AC system FORD MUSTANG 2003 Workshop Manual

PINPOINT TEST L: THE TRACTION CONTROL IS INOPERATIVE—
DOES NOT OPERATE CORRECTLY K8 CHECK THE RR ABS VALVE OPERATION
z
NOTE: Trigger must be depressed twice.
Each depress runs the pump motor for two
seconds.
z Trigger the anti- lock brake control module
active command PMP MOTOR ON for four
seconds.
z Apply moderate brake pedal effort.
z Have an assistant attempt to rotate the RR
wheel while the pump motor is running.
z Does the RR wheel rotate? Yes
INSTALL a new HCU; REFER to
Hydraulic Control Unit
. TEST the system
for normal operation.
No
GO to K9 .
K9 CHECK THE RR ABS VALVE RELEASE
z
Apply moderate brake pedal effort.
z Trigger the anti- lock brake control module
active command RF INLET and RF OUTLET.
z NOTE: The scan tool will energize the valves
for only two seconds per trigger press.
z Have an assistant rotate the RR wheel
immediately after depressing trigger.
z Does the RR wheel rotate? Yes
The ABS system is operating correctly.
No
GO to
K10 .
K10 CHECK FOR DTCS
z
Carry out the anti- lock brake control module
self- test.
z Are any DTCs retrieved? Yes
GO to the Anti-
Lock Brake Control Module
Diagnostic Trouble Code (DTC) Index.
No
INSTALL a new HCU; REFER to
Hydraulic Control Unit . TEST the system
for normal operation. Test Step Result / Action to Take
L1 CHECK THE TRACTION CONTROL SWITCH CIRCUITRY
z
Key in OFF position.
z Disconnect: Instrument Cluster C251.
z Key in ON position.
z Measure the voltage between instrument cluster C251 Pin 9,
Circuit 959 (GY), harness side and ground, while depressing
and releasing the traction control switch.
z Is the voltage greater than 10 volts with the traction control
switch depressed and zero volts with the traction control
switch released? Yes
INSTALL a new
instrument cluster,
REFER to
Section 413 -
01 . TEST the system
for normal operation.
No
GO to L2 . Klj . 17 ba
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PINPOINT TEST M: THE TRACTION CONTROL INDICATOR IS
INOPERATIVE—
TRACTION CONTROL SWITCH L2 CHECK CIRCUIT 959 (GY) FOR AN OPEN
z
Key in OFF position.
z Disconnect: Traction Control Switch C239.
z Measure the resistance between instrument cluster C251 Pin 9,
Circuit 959 (GY), harness side and traction control switch C239
Pin 4, Circuit 959 (GY), harness side.
z Is the resistance less than 5 ohms? Yes
GO to
L3 .
No
REPAIR the circuit.
TEST the system for
normal operation. L3 CHECK CIRCUIT 489 (PK/BK) FOR AN OPEN
z
Key in ON position.
z Measure the voltage between traction control switch C239 Pin
3, Circuit 489 (PK/BK), harness side and ground.
z Is the voltage greater than 10 volts? Yes
INSTALL a new traction
control switch. TEST the
system for normal
operation.
No
REPAIR the circuit.
TEST the system for
normal operation.
Test Step Result / Action to
Take M1 CHECK CIRCUIT 960 (BK/LB)
z
Key in OFF position.
z Disconnect: Instrument Cluster C251.
z Disconnect: Traction Control Switch C239.
z Measure the resistance between instrument cluster C251 Pin 8,
Circuit 960 (BK/LB), harness side and traction control switch C239
Pin 5, Circuit 960 (BK/LB), harness side; and between instrument
cluster C251 Pin 8, Circuit 960 (BK/LB), harness side and ground. Yes
GO to
M2 .
No Klj . 18 ba
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z
Is the resistance less than 5 ohms between the instrument
cluster and traction control switch and greater than 10,000
ohms between instrument cluster and ground? M2 CHECK CIRCUIT 489 (PK/BK) FOR AN OPEN
z
Key in ON position.
z Measure the voltage between traction control switch C239 Pin 3,
Circuit 489 (PK/BK), harness side and ground.
z Is the voltage greater than 10 volts? Yes
GO to
M3 .
No
REPAIR the circuit.
TEST the system
for normal
operation. M3 CHECK THE TRACTION CONTROL SWITCH INDICATOR
z
Key in OFF position.
z Connect: Traction Control Switch C239.
z Key in ON position.
z Momentarily connect a fused (10A) jumper wire between instrument
cluster C251 Pin 8, Circuit 960 (BK/LB), harness side and ground,
while observing the traction control switch indicator.
z Does the traction control switch indicator illuminate? Yes
INSTALL a new
instrument cluster;
REFER to
Section 413 - 01 . TEST the
system for normal
operation.
No
INSTALL a new
traction control
switch. TEST the
system for normal
operation. Klj . 19 ba
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REMOVAL AND INSTALLATION
Hydraulic Control Unit
Removal
1. Disconnect the battery ground cable(14301).
2. Disconnect the anti- lock-brake control module electrical connector.
3. NOTE: The 4 wheel anti- lock brake system (4WABS) with traction control is shown , the
4WABS without traction control system is similar with one less hydraulic line.
NOTE: Plug brake lines to prevent any brake fluid loss.
Disconnect the brake lines from the hydraulic control unit (HCU).
4. Remove the HCU bracket nuts to HCU.
5. Remove the HCU.
SECTION 206-
09B: Anti-Lock Control — Traction Control 2003 Mustang Workshop Manual Klj . 1 ba
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6. Remove the pump motor electrical connector.
7. Remove the anti-
lock-brake control module screws.
8. Remove the anti- lock-brake control module from the HCU.
Installation 1. NOTE: The brake system must be bled after the HCU is installed or replaced. Refer to Section 206 - 00 .
To install, reverse the removal procedure. Klj . 2 ba
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REMOVAL AND INSTALLATION
Module
Removal
1. Remove the hydraulic control unit (HCU). Refer to Hydraulic Control Unit .
2. Remove the pump motor electrical connector.
3. Remove the anti- lock-brake control module screws.
4. Remove the anti- lock-brake control module from the HCU.
Installation
1. NOTE: The brake system must be bled after the HCU is installed or replaced. Refer to Section 206 - 00 .
To install, reverse the removal procedure.
SECTION 206-
09B: Anti-Lock Control — Traction Control 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 211-
00: Steering System — General Information 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants
Motorcraft MERCON® Multi-Purpose (ATF) Transmission Fluid XT-
2- QDX MERCON®
Power Steering Gear
Turning effort 2.27 Kg (5.0 lb)
Turns lock-to-
lock 2.38
Power Steering Purge Vacuum
Vacuum 68-
85 kPa (20- 25 in/hg) Power Steering Pump —
CII Flow 9.8 liters/minute
(2.6 gpm)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at 1,500 rpm Pressure 1,034 kPa
(150 psi)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at 1,500 rpm Minimum capacity 3.4 liters/minute
(0.9 gpm)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at idle
Pressure at 5,102 kPa (750
psi) Relief pressure 7,240-8,400 kPa
(1,050-1,230 psi) Power Steering Pump —
CIII Flow 9.8 liters/minute
(2.6 gpm)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at 1,500 rpm Pressure 1,034 kPa
(150 psi)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at 1,500 rpm Minimum capacity 4.7 liters/minute
(1.25 gpm)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at idle
Pressure at 5,171 kPa (750 psi) Klj . 1 ba
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DESCRIPTION AND OPERATION
Steering System
The steering system has a typical rack-and-
pinion design consisting of the following:
Steering System Components — 3.8L Engine (CII Power Steering
Pump)
Steering System Components — 4.6L Engine (CIII Power Steering Pump) SECTION 211-
00: Steering System — General Information 2003 Mustang Workshop Manual Item Part Number Description
1 3A714 Power steering hose
2 3A674 Power steering pump
3 3493 Power steering hose
4 3504 Steering gear
5 3A130 Tie-
rod end 6 3493 Power steering hose
7 3D746 Power steering fluid cooler Klj . 1 ba
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DIAGNOSIS AND TESTING
Steering System
Inspection and Verification
CAUTION: Do not hold the steering wheel (3600) at the stops for an extended amount of
time. Damage to the power steering pump (3A674) will result. NOTE: Make the following preliminary checks before repairing the steering system:
SECTION 211-
00: Steering System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Dial Thermometer 0-
220°F
023- R0007 or Equivalent Hand Held Automotive Meter
105-
R0053 or Equivalent Power Steering Analyzer
211-
F001 (014- 00207) or
Equivalent Spring Scale
211-
034 (T74P-3504- Y) Tach Adapter
418-
F102 (007- 00061) or
Equivalent Tie-
Rod End Remover Tool
211- 001 (TOOL- 3290-D) or
Equivalent Klj . 1 ba
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1. Verify the customer concern by operating the steering system.
2. Inspect Tires
zCheck the tire pressure. Refer to the Vehicle Certification (VC) label.
z Verify that all tires are sized to specification.
z Check the tires for damage or uneven wear.
3. Belt and Tensioner Check zRefer to Section 303 - 05 for diagnosis and testing of the accessory drive system.
4. Fluid Level Check zVerify that the power steering fluid level is within the appropriate indicated range, hot for
the 3.8L engine and cold for the 4.6L engine. Add Motorcraft MERCON® Multi- Purpose
ATF XT -2-QDX or MERCON® equivalent.
5. Air Bleeding zVerify that there is no air in the power steering system. Run the engine (6007) until it
reaches normal operating temperature. Turn the steering wheel to the left and right
several times without hitting the stops. If any air bubbles are present, refer to Purging —
CII Power Steering Pump or
Purging — CIII Power Steering Pump in this section.
External Leak Check — Typical Power Rack-and-Pinion Steering Gear Klj . 2 ba
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