wiring FORD MUSTANG 2003 Workshop Manual

Item Part Number Description
1 7902 Torque converter
2 7A248 Front pump seal
3 7A248 Front pump seal
4 N605789-S101 Bolt
5 7A106 Front pump body assembly
6 7A136 Pump gasket
7 390318-
S2 Pipe plug —
1/8 —27 Dryseal tapered 8 7005 Case
9 7034 Vent
10 N811757-S100 Speed sensor seal
11 7H103 Output shaft speed (OSS) sensor
12 7B498 Manual control lever seal assembly
13 7086 Extension housing gasket
14 7A039 Extension housing
15 N803737-S1101 Bolt —
M8-1.25 x 30 15 N606047-S101 Bolt —
M8-1.25 x 70 15 N803521-S1101 Bolt —
M8-1.25 x 1.25 x 0.54 15 N811524-S101 Bolt —
M8-1.25 x 42 16 7052 Oil seal
17 7Z276 Seal —
bulkhead assembly 18 7G276 Bulkhead assembly wiring connector
19 7G276 Molded lead frame
20 7A194 Transmission fluid pan
21 7A191 Gasket Klj . 2 ba
52003 Mustang Workshop Manual
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·
Seals, piston damaged ·
Inspect for damage. Repair as required. ·
Check ball missing or
damaged ·
Friction elements damaged
or worn Low/Reverse Band
·
Band, servo, anchor pins
damaged or worn ·
Inspect for damage. Repair as required.
Engagement Concern: Harsh Reverse Possible Component Reference/Action
203 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, TFT sensor, EPC
solenoid ·
Carry out Self-Test; refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Carry out engagement test, EPC test
and Go To Pinpoint Test B or
Go To Pinpoint Test D . Check idle
speed. Repair as required. Clear DTCs, road test and repeat Self-
Test. 303 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Engine Driveline
·
Looseness in the
driveshaft, U- joints or the
engine mounts ·
Repair as required. Shift Linkage
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable, verify
that the digital TR sensor is correctly adjusted. Adjust the digital
TR sensor as necessary. Incorrect Pressures
·
High line pressure, high
EPC pressure ·
Check pressure at line and EPC pressure taps; refer to Line
Pressure Chart for specifications. If high, check the following
components: main controls, oil filter and seal assembly. Fluid Filter and Seal
Assembly
·
Plugged or damaged ·
Install a new filter and seal assembly. ·
Filter seal damaged Main Controls
·
No. 6 shuttle ball, No. 5
check ball, manual valve,
main regulator valve stuck,
damaged or missing ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. Klj . 6 ba
312003 Mustang Workshop Manual
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·
Gasket damaged ·
Inspect for damage and install a new gasket. ·
EPC solenoid stuck or
damaged ·
Inspect for damage, contamination. Carry out EPC test in Routine
No. 203. Repair as required. Low Reverse Servo
·
Seals (piston and cover)
damaged ·
Inspect for damage. Repair as required. ·
Servo cover retaining ring
assembled incorrectly ·
Anchor pins (case)
damaged Pump Assembly
·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Porosity/cross leaks ·
Inspect pump assembly. Install new as required. ·
Gasket damaged ·
Inspect for damage and install a new gasket. ·
No. 1 and No. 2 seal rings
damaged ·
Inspect for damage. Repair as required. Reverse Clutch Assembly
·
Seals, piston damaged ·
Inspect for damage. Repair as required. ·
Check ball missing or
damaged ·
Friction elements
damaged, worn ·
Return spring piston
damaged, worn Low Reverse Band
·
Band, servo, anchor pin
damaged or worn ·
Inspect for damage. Repair as required.
Engagement Concern: Harsh Forward Possible Component Reference/Action
204 —
ELECTRICAL ROUTINE Powertrain Control
System
·
Electrical inputs/outputs,
vehicle wiring
harnesses, PCM, TFT
sensor, EPC solenoid ·
Carry out Self- Test; refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Carry out engagement test and EPC
test. Go To Pinpoint Test B or
Go To Pinpoint Test D . Check idle
speed. Repair as required. Clear DTCs, road test and repeat Self-
Test. 304 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Engine Driveline
·
Looseness in the
driveshaft, U- joints or ·
Repair as required. Klj . 7 ba
312003 Mustang Workshop Manual
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Shift Concerns: Some/All Shifts Missing
Possible Component Reference/Action
210 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses, PCM,
shift solenoids, output shaft
speed (OSS) sensor, digital TR
sensor ·
Carry out Self-Test; refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Go To Pinpoint Test A ,
Go To Pinpoint Test C or
Go To Pinpoint Test E . Repair as
required. Clear DTCs, road test and repeat Self- Test. 310 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Shift Linkage, Digital TR Sensor
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable,
verify that the digital TR sensor is correctly adjusted. Adjust
the digital TR sensor as necessary. ·
Refer to the following shift routine(s) for further diagnosis:
„ Shift 1- 2, Routine 220/320
„ Shift 2- 3, Routine 221/321
„ Shift 3- 4, Routine 222/322
„ Shift 4- 3, Routine 223/323
„ Shift 3- 2, Routine 224/324
„ Shift 2- 1, Routine 225/325
Shift Concerns: Timing Concerns — Early/Late Possible Component Reference/Action
211 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, shift solenoids, EPC
solenoid, TFT sensor, OSS ·
Carry out Self- Test. Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Go To Pinpoint Test A ,
Go To Pinpoint Test C or
Go To Pinpoint Test E . Repair as required.
Clear DTCs, road test and repeat Self- Test. 311 —
HYDRAULIC/MECHANICAL ROUTINE Other
·
Tire size change, axle ratio
change ·
Verify vehicle has original equipment. Refer to Certification
Label and Safety Standard Certification Label. Changes in tire
size or axle ratio will affect shift timing. Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Powertrain Control System
·
Engine driveability concerns ·
Refer to Routine 253. Klj . 11 ba
312003 Mustang Workshop Manual
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Incorrect Pressures
·
Line pressure, EPC pressure ·
Check pressure at line and EPC taps; refer to Line Pressure
Chart for specifications. If not OK, check the main controls. If
OK, refer to the shift routine(s) for further diagnosis:
„ Shift 1- 2, Routine 320
„ Shift 2- 3, Routine 321
„ Shift 3- 4, Routine 322
„ Shift 4- 3, Routine 323
„ Shift 3- 2, Routine 324
„ Shift 2- 1, Routine 325 Main Controls
·
EPC solenoid, stuck or
damaged hydraulically or
mechanically ·
Inspect for damage, contamination. Carry out EPC tests in
Routine No. 211. Repair as required. ·
Valves, accumulators, seals
stuck or damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
Solenoid screen blocked or
damaged ·
Clean or install a new screen.
Shift Concerns: Timing Concerns — Erratic/Hunting Possible Component Reference/Action
212 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, shift
solenoids, torque converter clutch
(TCC) solenoid, digital TR sensor,
output shaft speed (OSS) ·
Carry out Self- Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for
diagnosis. Go To Pinpoint Test A ,
Go To Pinpoint Test C or
Go To Pinpoint Test E . Repair as required. Clear
DTCs, road test and repeat Self- Test. ·
Poor engine performance ·
Refer to Routine 253. 312 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Main Controls
·
Valves, accumulators, seals,
assembled wrong, stuck or
damaged ·
Inspect for damage. Repair as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
Solenoid screen blocked or
damaged ·
Clean or install a new screen. Torque Converter Clutch
·
Torque converter ·
Refer to Torque Converter Operation Concerns:
Cycling/Shudder/Chatter Hydraulic/Mechanical Routine
342. Specific Shifts
·
Refer to the following shift routine(s) for further diagnosis: Klj . 12 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

„
Shift 1- 2, Routine 320
„ Shift 2- 3, Routine 321
„ Shift 3- 4, Routine 322
„ Shift 4- 3, Routine 323
„ Shift 3- 2, Routine 324
„ Shift 2- 1, Routine 325
Shift Concerns: Feel — Soft/Slipping Possible Component Reference/Action
213 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, EPC solenoid, OSS ·
Carry out Self- Test. Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Go To Pinpoint Test D or
Go To Pinpoint Test E . Repair as required. Clear DTCs, road test and
repeat Self- Test. ·
Engine driveability concerns ·
Refer to Routine 253. 313 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Incorrect Pressures
·
Low line pressure, low EPC
pressure ·
Check pressures at line and EPC taps; refer to Line Pressure
Chart for specifications. If pressures are low or all shifts are
soft/slipping, go to main controls. If pressures are OK and a
specific shift is soft/slipping, refer to the following routine(s) for
further diagnosis:
„ Shift 1- 2, Routine 320
„ Shift 2- 3, Routine 321
„ Shift 3- 4, Routine 322
„ Shift 4- 3, Routine 323
„ Shift 3- 2, Routine 324
„ Shift 2- 1, Routine 325 Main Controls
·
Main regulator valve,
overdrive servo regulator
valve stuck, damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
EPC solenoid stuck or
damaged ·
Inspect for damage and contamination. Carry out EPC tests in
Routine 213. Repair as required. Case
·
1- 2 accumulator stuck or
damaged ·
Inspect for damage. Repair as required. Filter and Seal Assembly
·
Filter plugged, damaged ·
Inspect for damage. Install a new filter as required. ·
Seal damaged or cut ·
Inspect for damage. Replace as required. Klj . 13 ba
312003 Mustang Workshop Manual
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Shift Concerns: Feel —
Harsh Possible Component Reference/Action
214 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, EPC solenoid, OSS ·
Carry out Self- Test. Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Go To Pinpoint Test D or
Go To Pinpoint Test E . Repair as required. Clear DTCs, road test and
repeat Self- Test. ·
Engine driveability concerns ·
Refer to Routine 253. 314 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Incorrect Pressures
·
High line pressure, high EPC
pressure ·
Check pressures at line and EPC taps. See the to Line Pressure
Chart for specifications. If pressures are high or all shifts are
harsh, go to Main Controls. If pressures are OK and a specific
shift is harsh, refer to the following shift routine(s) for further
diagnosis:
„ Shift 1- 2, Routine 320
„ Shift 2- 3, Routine 321
„ Shift 3- 4, Routine 322
„ Shift 4- 3, Routine 323
„ Shift 3- 2, Routine 324
„ Shift 2- 1, Routine 325 Main Controls
·
Main regulator valve,
overdrive servo regulator
valve stuck, damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
EPC solenoid stuck or
damaged ·
Inspect for damage or contamination. Carry out EPC tests in
Routine 214. Repair as required.
Shift Concerns: No 1st Gear, Engages In Higher Gear Possible Component Reference/Action
215 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, shift
solenoids, digital transmission
range TR sensor ·
Carry out Self- Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for diagnosis
and testing of the Powertrain Control System. Go To Pinpoint Test A or
Go To Pinpoint Test C . Repair as
required. Clear DTCs, road test and repeat Self- Test. 315 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR Sensor
·
Damaged or incorrectly adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment. Refer to Section 307 - 05 . Adjust transmission
shift cable as necessary. After repairing transmission shift
cable, verify that the digital TR sensor is correctly adjusted. Klj . 14 ba
312003 Mustang Workshop Manual
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X = pressure applied Adjust the digital TR sensor as necessary.
Incorrect Pressures
·
Low reverse clutch pressure,
low reverse band pressure, low
line pressure
z Forward Off, Intermediate
Off, Direct X
z Forward Off, Intermediate
X, Direct Off
z Forward Off, Intermediate
X, Direct X
z Forward X, Intermediate
Off, Direct X
z Forward X, Intermediate X,
Direct Off
z Forward X, Intermediate X,
Direct X
z Forward X, Intermediate
Off, Direct Off ·
Check for which pressures are on and refer to Band/Clutch
Application Chart 601 and corresponding routines.
„ 324, 301
„ 325, 301
„ 323, 324, 325, 301
„ 324
„ 325
„ 323, 324, 325
„ Refer to appropriate mechanical diagnosis. Mechanical
·
Bands, clutches or seals
damaged or worn ·
Refer to Transmission Disassembly and Assembly.
Shift Concerns: No Manual 1st Gear Possible Component Reference/Action
216 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses, PCM,
shift solenoids, digital TR
sensor ·
Carry out Self- Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for diagnosis
and testing of the Powertrain Control System. Go To Pinpoint Test A or
Go To Pinpoint Test C . Repair as required. Clear
DTCs, road test and repeat Self- Test. 316 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Cable, Digital TR
Sensor
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable,
verify that the digital TR sensor is correctly adjusted. Adjust
the digital TR sensor as necessary. Incorrect Pressures
·
Low reverse clutch pressure,
low reverse band pressure, low
line pressure, low EPC
pressure ·
Check pressure at line and EPC pressure taps; refer to Line
Pressure Chart for specifications. If pressures are low, check
the following components: oil filter and seal assembly, main
controls, reverse clutch assembly and reverse servo
assembly. Fluid Filter and Seal Assembly
·
Plugged or damaged ·
Install a new filter and seal assembly. Klj . 15 ba
312003 Mustang Workshop Manual
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Main Controls
·
No. 6 shuttle ball, manual
valve, main regulator valve, low
servo modulator valve stuck,
damaged or assembled
incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Low Reverse Servo
·
Seals (piston and cover)
damaged ·
Inspect for damage. Repair as required. ·
Servo cover retaining ring assembled incorrectly. ·
Anchor pins (case) damaged.
Shift Concerns: No Manual 2nd Gear Possible Component Reference/Action
217 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, shift solenoids, digital
TR sensor ·
Carry out Self- Test. Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Go To Pinpoint Test A or
Go To Pinpoint Test C . Repair as required. Clear DTCs, road test
and repeat Self- Test. 317 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Cable, Digital TR
Sensor
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable,
verify that the digital TR sensor is correctly adjusted. Adjust the
digital TR sensor as necessary. Main Controls
·
3- 4 shift valve, 1- 2 and 2-3
shift valve, 3- 4 capacity
modulator valve stuck,
damaged or assembled
incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Gaskets damaged ·
Inspect for damage and install a new gasket.
Shift Concerns: 1-2 Shift (Automatic) Possible Component Reference/Action
220 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, ·
Carry out Self- Test. Refer to the Powertrain Control/Emissions Klj . 16 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

vehicle wiring harnesses,
PCM, shift solenoids,
OSS Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Go To Pinpoint Test A or
Go To Pinpoint Test E . Repair as required. Clear DTCs, road test and
repeat Self- Test. ·
Poor engine performance ·
Refer to Routine 253. 320 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR
Sensor
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift cable
as necessary. After repairing transmission shift cable, verify that the
digital TR sensor is correctly adjusted. Adjust the digital TR sensor
as necessary. Incorrect Pressures
·
Intermediate clutch
pressure, line pressure ·
Check pressure at line and intermediate clutch taps; see the line
pressure chart for specifications. If not OK, check the main controls. Main Controls
·
1- 2 shift valve, stuck or
damaged ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specification. ·
Shift solenoid SSA
malfunction ·
Activate solenoid using scan tool. If solenoid operation cannot be
felt when placing hand on solenoid, install a new solenoid. Inspect
O- rings for damage. Repair as required. ·
Gasket damaged ·
Inspect for damage and install a new gasket. ·
No. 8 ball not seating ·
Inspect for damage. Repair as required. Case
·
1- 2 accumulator stuck or
damaged ·
Inspect for damage. Repair as required. Pump
·
Porosity/cross leaks,
balls missing, damaged
or leaking ·
Inspect for porosity/leaks, balls missing. Install a new pump as
required. ·
Gasket damaged ·
Inspect for damage and install a new gasket. Intermediate Clutch
Assembly
·
Seals damaged ·
Inspect for damage. Repair as required. ·
Piston damaged ·
Inspect for damage. Repair as required. ·
Friction elements
damaged or worn ·
Inspect for damage. Repair as required. Intermediate One-
Way
Clutch Assembly ·
Not holding or damaged ·
Inspect for damage. Repair as required. Planetary One-
Way Clutch
Assembly ·
Not overrunning or
damaged ·
Inspect for damage. Repair as required. 1-
2 Accumulator ·
Damaged accumulator ·
Inspect for damage. Repair as required. Klj . 17 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...