AC system FORD MUSTANG 2003 Workshop Manual

GENERAL PROCEDURES
Fill
1. WARNING: Do not mix oil types, any mixture or any unapproved oil can lead to seal
deterioration and leaks. A leak can ultimately cause loss of fluid, which can result in a
loss of power steering assist.
Check the fluid level. If necessary, fill the reservoir to the correct level.
zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
2. Remove the fuel pump fuse from the battery junction box.
3. Raise the front wheels off the floor. For additional information, refer to Section 100 - 02 .
4. CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow the
starter to cool for 1 minute before cranking again. Premature starter failure can occur.
CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump will occur.
Turn the steering wheel from stop- to-stop while cranking the engine.
5. Lower the vehicle.
6. CAUTION: Do not overfill the reservoir.
Check the fluid level. If necessary, fill the reservoir to the correct level. zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
7. Install the fuel pump fuse.
SECTION 211-
00: Steering System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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DESCRIPTION AND OPERATION
Power Steering
System View
Steering System Components —
3.8L Engine Steering System Components — 4.6L Engine SECTION 211-
02: Power Steering 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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REMOVAL AND INSTALLATION
Reservoir —
CIII Pump
Removal 1. Remove the bolts.
2. Disconnect the power steering hoses. Remove the reservoir.
Installation 1. To install, reverse the removal procedure.
2. Fill and leak check the power steering system. For additional information, refer to Section 211 -
00 .
SECTION 211-
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5. To install, reverse the removal procedure.
zUsing the special tool, install a new seal ring.
6. Fill and leak check the power steering system. For additional information, refer to Section 211 -
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5. To install, reverse the removal procedure.
zUsing the special tool, install a new seal ring.
6. Fill and leak check the power steering system. For additional information, refer to Section 211 -
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REMOVAL AND INSTALLATION
Hose
Removal and Installation
CAUTION: While servicing the power steering system, make sure to plug all open hoses,
line fittings, and fluid ports to prevent the entry of contaminants or premature failure of the
power steering components can result.
1. Refer to the System View illustration in Description and Operation for the hose routing and retention points.
2. When connecting a fitting with a seal ring, a new seal ring must be installed. zThe special tool is used to install the return line connector seal and the pressure line
connector seal.
3. Fill, purge and leak check the system. For additional information, refer to Section 211 - 00 .
SECTION 211-
02: Power Steering 2003 Mustang Workshop Manual Special Tool(s)
Installer Set, Teflon Seal
211-
D027 (D90P-3517- A) or
equivalent Klj . 1 ba
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REMOVAL AND INSTALLATION
Cooler —
Fluid
Removal 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Disconnect the power steering hoses.
3. Remove the bolt and routing bracket.
4. Remove the bolts and the power steering fluid cooler.
Installation 1. To install, reverse the removal procedure.
2. Fill and leak check the power steering system. For additional information, refer to Section 211 -SECTION 211-
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2. Fill and leak check the power steering system. For additional information, refer to
Section 211 -
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NOTE:
All fasteners are important because they can affect the performance of vital parts and systems.
Incorrect installation of the fasteners can result in major repair expenses. They must be installed new
with fasteners of the same part number if installation becomes necessary. Do not install a new part of
lesser quality or substitute a design. Torque values must be used as specified during assembly to
make sure these parts function correctly.
The body of the steering column (3C529) is made of magnesium die castings. The steering column is
attached to a support that is an integral part of the instrument panel. The lower attachments of the
steering column are through a bracket that bends during collapse. The upper attachments are through
plastic shear modules that separate from the main casting during collapse. A clip and washer are
attached to the shear modules to reduce steering column shake and to assist in installation of the
steering column. 45 N621906 Nut
46 N803942 Bolt
47 3A525 Intermediate shaft coupling
48 11A128 Ignition key warning switch terminal
49 N806583 Bearing housing retaining screw
50 N804865-
S58 Screw
51 14A06 Wire connector bracket
52 3E715 Lock lever lower actuator
53 3E691 Lock pawl
54 3F723 Actuator housing
55 3E745 Lock actuator cover
56 3F719 Ignition/shifter interlock cable
57 N808124-
58M Screw
58 3D655 Position spring
59 3D656 Tilt flange bumper
60 N806582 Tilt pivot screws
61 11582 Ignition switch lock cylinder
62 3E700 Lock housing bearing
63 3E717 Lock gear
64 3530 Upper shroud
65 3511 Lock cylinder housing
66 N805857 Lock actuator lever pin
67 3D681 Bearing retainer Klj . 3 ba
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GENERAL PROCEDURES
Supplemental Restraint System (SRS) Deactivation and
Reactivation
Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint
system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury
in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium
hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your
hands with soap and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air
bag deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be installed
new, not repainted.
WARNING: The restraint system diagnostic tool is for restraint system service only.
Remove from vehicle prior to road use. Failure to remove could result in injury and possible
violation of vehicle safety standards.
1. WARNING: To avoid accidental deployment and possible personal injury, the
backup power supply must be depleted before repairing or replacing any front or side air
bag supplemental restraint system (SRS) components and before servicing, replacing,
adjusting or striking components near the front or side air bag sensors, such as doors,
instrument panel, console, door latches, strikers, seats and hood latches.
Please refer to the appropriate vehicle shop manual to determine location of the front air
bag sensors.
The side air bag sensors are located at or near the base of the B- pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and
wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). SECTION 211-
04: Steering Column 2003 Mustang Workshop Manual Special Tool(s)
Diagnostic Tool, Restraint
System (2 Req'd)
418-
F088 (105- R0012) Klj . 1 ba
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