torque FORD MUSTANG 2003 Workshop Manual

a
Carry out electrical routine first.
Diagnostic Routines Engagement Concerns
No Forward 201 301
No REVERSE 202 302
Harsh REVERSE 203 303
Harsh Forward 204 304
Delayed/Soft Reverse 205 305
Delayed/Soft Forward 206 306
Shift Concerns
Some/All Shifts Missing 210 310
Timing Concerns
—
Early/Late 211 311
—Erratic/Hunting 212 312
Feel
—
Soft/Slipping 213 313
—
Harsh 214 314
No 1st Gear, Engages in Higher Gear 215 315
No Manual 1st Gear 216 316
No Manual 2nd Gear 217 317
Torque Converter Operation Concerns
No Apply 240 340
Always Applied/Stalls Vehicle 241 341
Cycling/Shudder/Chatter 242 342
Other Concerns
No Engine Braking in 2nd Gear, Manual 2nd or Manual 1st
Position 250 350
Gearshift Lever Efforts High 251 351
External Leaks 252 352
Vehicle Driveability Concerns 253 353
Noise/Vibration in Forward or Reverse 254 354
Engine Will Not Crank 255 355
No PARK (P) Range 256 356
Overheating 257 357
Engagement Concern: No Forward Possible Component Reference/Action
201 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 301 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect as under Fluid Condition Check; refer to Verification of Klj . 3 ba
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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
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Pump
·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
Porosity/cross leaks ·
Inspect for leak/porosity. Install a new pump as required. Intermediate Clutch Assembly
·
Piston damaged ·
Inspect for damage. Repair as required. ·
Friction elements damaged,
worn ·
Inspect for damage. Repair as required. ·
End clearance incorrect ·
Inspect and correct; refer to Transmission Assembly. Intermediate One-
Way Clutch ·
Damaged ·
Inspect for damage. Repair as required. ·
Intermediate one- way clutch
retaining snap ring not seated ·
Inspect for damage. Repair as required. Planetary One-
Way Clutch ·
Not holding or damaged ·
Inspect for damage. Repair as required.
Torque Converter Clutch Operation Concerns: No Apply Possible Component Reference/Action
240 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, torque
converter clutch (TCC) 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 B or
Go To Pinpoint Test E .
Repair as required. Clear codes, road test and repeat
Self- Test. 340 —
HYDRAULIC/MECHANICAL ROUTINE 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
·
Low line pressure, low EPC pressure ·
Check pressure at line and EPC taps; refer to Line
Pressure Chart for specifications. If pressure is low,
check EPC and main regulator valve. If within
specifications, check the main controls. Main Controls
·
Solenoid pressure regulator valve,
manual valve, bypass clutch control
valve and plunger, converter
pressure limit valve, drain back valve
stuck, damaged or assembled
incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to specifications ·
Tighten bolts to specifications. ·
Solenoid screen blocked or damaged ·
Clean or install a new screen. ·
TCC solenoid malfunction ·
Activate solenoid using scan tool. If solenoid operation Klj . 23 ba
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cannot be felt when placing hand on solenoid, install a
new solenoid. Inspect O- rings for damage. Repair as
required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Pump Assembly
·
Bolts not tightened to specifications ·
Tighten bolts to specifications. ·
Porosity/cross leaks, balls leaking ·
Inspect for porosity/leaks, ball missing. Install a new
pump as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Input Shaft
·
Seals damaged ·
Inspect for damage. Repair as necessary. Torque Converter Assembly
·
Leakage, friction material damaged,
internal seals damaged ·
Inspect torque converter. Repair or install a new or
remanufactured torque converter as required.
Torque Converter Clutch Operation Concerns: Always Applied/Stalls Vehicle Possible Component Reference/Action
241 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, torque converter clutch
(TCC) solenoid, TFT 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 B or
Go To Pinpoint Test A . Repair as required. Clear DTCs, road test
and repeat Self- Test. 341 —
HYDRAULIC/MECHANICAL ROUTINE Main Control
·
Drain back valve, torque
converter clutch (TCC) and
plunger stuck, damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
TCC solenoid 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. ·
No. 7 ball incorrect seating ·
Inspect for damage. Repair as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Pump Assembly
·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Ball missing, leaking,
porosity/cross leaks ·
Inspect for porosity/leaks, balls missing. Install a new pump as
required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Input Shaft
·
Seals damaged ·
Inspect for damage. Repair as required. Torque Converter Assembly Klj . 24 ba
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·
No end clearance ·
Inspect converter and install a new or remanufactured torque
converter as required. ·
Piston plate damaged or stuck
to cover ·
If cover is heat- stained, install a new converter and determine
the cause of the overheat condition.
Torque Converter Clutch Operation Concerns: Cycling/Shudder/Chatter Possible Component Reference/Action
242 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, torque
converter clutch (TCC) 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 E . Repair as required. Clear
DTCs, road test and repeat Self- Test. ·
Speed control equipped vehicles ·
Evaluate with speed control off. 342 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Condition ·
Inspect fluid condition. If burnt, drain fluid and converter.
Install a new fluid and filter assembly. Bring vehicle to
normal operating temperature. Carry out Transmission
Drive Cycle Test. Carry out Transmission Self- Test. If
condition still exists, continue diagnostics. Main Controls
·
Solenoid pressure regulator valve,
No. 7 check ball, bypass clutch
control valve and plunger, converter
pressure limit valve stuck, damaged
or assembled incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to specifications ·
Tighten bolts to specifications. ·
Solenoid screen blocked or damaged ·
Clean or install a new screen. ·
TCC solenoid 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. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Pump Assembly
·
Bolts not tightened to specification ·
Tighten bolts to specification. ·
Porosity/cross leaks, missing balls or
leaking ·
Inspect for porosity/leaks or missing balls. Install a new
pump as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Input Shaft
·
Seals damaged ·
Inspect for damage. Repair as required. Torque Converter
·
Excessive end clearance ·
Inspect converter. Install a new or re- manufactured
torque converter as required.
Other Concerns: No Engine Braking In Manual 2nd Or Manual 1st Position Klj . 25 ba
312003 Mustang Workshop Manual
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mechanism damaged
Main Controls
·
Manual valve stuck or
damaged ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications.
Other Concerns: External Leaks Possible Component Reference/Action
252 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, sensor
seals leaking (digital TR, OSS,
vehicle speed sensor VSS, if
equipped, or transmission connector) ·
Inspect for leakage and repair as required. 352 —
HYDRAULIC/MECHANICAL ROUTINE Case
·
Case vent, case porosity, case
cracked ·
Check the vent for free breathing. Check the fluid level.
Check the transmission for overheat conditions. Repair
as required. Seals/Gaskets
·
Leakage at gaskets, seals, etc. (refer
to external sealing illustration for
potential leak locations) ·
Remove all traces of lubricant on exposed surfaces of
the transmission. Check the vent for free breathing.
Operate the transmission at normal temperatures and
perform fluid leakage check. Repair as required. Other
·
Cooler fitting, cooler lines pressure
tap, converter drain plug, band
anchor pins ·
Locate the source of the leak. Repair as required.
Other Concerns: Poor Vehicle Performance Possible Component Reference/Action
253 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, shift solenoids,
digital TR sensor, torque
converter clutch (TCC) solenoid,
transmission fluid temperature
(TFT) 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 B or
Go To Pinpoint Test C . Repair as required. Clear codes, road test and
repeat Self- Test. Also refer to Routines 241/341 Torque
Converter Operation Concern: Always Applied. ·
Engine driveability concerns ·
Inspect air intake/air filter system. Check the fuel system
and fuel pressure. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual. Inspect the
exhaust system for restriction. Refer to Section 309 - 00 .
353 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR Sensor Klj . 27 ba
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·
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. Verify Correct Shift Scheduling
and Engagements
·
See Reference/Action ·
Go to the appropriate diagnostic routines. Torque Converter Clutch Always
Applied
·
See Reference/Action ·
Go to Hydraulic/Mechanical Routine 241/341. Torque Converter Clutch
·
Damaged ·
Inspect torque converter. Install a new converter as outlined.
Other Concerns: Noise/Vibration — Forward Or Reverse Possible Component Reference/Action
254 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 354 —
HYDRAULIC/MECHANICAL ROUTINE For Noises/Vibrations That Change With Engine
Speed
·
Converter components/balance weight ·
Locate source of disturbance. Repair as
required. ·
Fluid level (low) pump cavitation ·
Pump assembly ·
Engine drive accessories ·
Cooler lines grounding out ·
Flexplate For Noises/Vibrations That Change With Vehicle
Speed
·
Engine mounts loose or damaged ·
Locate source of disturbance and repair as
required. ·
Driveline concerns:
„ U-joints
„ Rear axle
„ Suspension
„ Modifications
1st Gear: „Low one- way clutch
„ Gearset
„ Friction elements ·
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
„ Torque Converter Cycling 242/342 ·
2nd Gear:
„ Intermediate one- way clutch
„ Intermediate clutch piston bleed hole out of Klj . 28 ba
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12 o'clock position
„ Friction elements ·
3rd Gear:
„ Torque converter
„ Case to planet support spring
„ Friction elements ·
4th Gear:
„ Gear set
„ Friction elements
„ Torque converter ·
Reverse:
„ Gear set
„ Friction elements ·
Output shaft splines worn or damaged Other Noises/Vibrations
·
Main controls, valve resonance ·
Shift cable:
„ Vibration
„ Grounding
„ Cooler lines
„ Grounding ·
Locate source of disturbance and repair as
required.
Other Concerns: Engine Will Not Crank Possible Component Reference/Action
255 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
engine starting system
hardware, 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 C . Repair and
adjust as required. 355 —
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.
Other Concerns: No Park (P) Range Possible Component Reference/Action
256 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 356 —
HYDRAULIC/MECHANICAL ROUTINE Klj . 29 ba
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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. Park Mechanism
·
Output shaft ring, parking brake pawl,
parking pawl return spring, park rod
guide cup, parking pawl shaft,
parking pawl actuating rod, manual
lever detent spring damaged or
assembled incorrectly ·
Inspect for damage or incorrect assembly and repair as
required.
Other Concerns: Overheating Possible Component Reference/Action
257 —
ELECTRICAL ROUTINE Refer to Routine 240/340, Torque Converter Operation Concern: No Apply
357 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Other
·
Damaged, blocked or reversed cooler lines or
restriction in the transmission oil cooler ·
Inspect for damage and correct
installation. Repair as required. Vehicle Concerns Causing Engine Overheating
·
Refer to the appropriate engine
cooling section. Main Controls
·
Drain back valve, torque clutch control valve, converter
limit valve stuck, damaged or assembled incorrectly ·
Inspect for damage and repair as
required. Torque Converter Clutch
·
No apply ·
Refer to Routine 240/340. Klj . 30 ba
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GENERAL PROCEDURES
Transmission Fluid Cooler —
Backflushing and Cleaning
1. CAUTION: Do not use any supplemental transmission fluid additives or cleaning
agents. The use of these products could cause internal transmission components to fail;
this will effect the operation of the transmission.
Conduct backflushing with a suitable torque converter/fluid cooler cleaner. Test your equipment
to make sure that a vigorous fluid flow is present before proceeding. Install a new filter in the
flush equipment if flow is weak or contaminated.
2. To aid in attaching the cleaner to the transmission steel cooler lines, connect two additional rubber hoses to the transmission end of the steel transmission cooler lines as described below.
zConnect the cleaner tank pressure line to the steel transmission cooler return line
(longest line).
z Connect a tank return hose to the steel transmission cooler pressure line (shorter line).
Place the outlet end of this hose in the solvent tank reservoir.
3. Turn on solvent pump and allow the solvent to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system).
4. Switch off the solvent pump and disconnect the solvent pressure hose from the transmission cooler return line.
5. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all solvent is removed.
6. Remove the rubber return hose from the remaining steel cooler line.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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