coolant FORD MUSTANG 2003 Workshop Manual

Stall Speed Test
WARNING: Apply the parking brake firmly while carrying out each stall test.
CAUTION: Carry out line pressure test prior to carrying out stall test. If the line pressure is
low at stall, do not carry out stall test or further transmission damage will occur.
The stall speed test checks:
zthe torque converter clutch operation and installation.
z the holding ability of the forward clutch.
z the reverse clutch (the low- reverse bands).
z the planetary one- way clutch.
z the engine driveability.
Conduct this test with the engine coolant and transmission fluid at correct levels and at normal
operating temperature.
Apply the parking brake firmly for each stall speed test. 1. Find the specified stall rpm for the vehicle; see the stall speed diagnosis chart. Use a grease pencil to mark the rpm on the dial of a tachometer.
2. Connect a tachometer to the engine.
3. NOTE: If the rpm recorded by the tachometer exceeds the maximum limits, release the
accelerator pedal immediately because clutch or band slippage is indicated.
In each of the following ranges (D), 2, 1, R, press the accelerator pedal to the floor and hold it ·
Reverse Clutch Low In Neutral Only ·
Valve Body Low In Overdrive Only ·
Forward Clutch ·
Valve Body Low In 1st Position Only ·
Forward Clutch ·
Valve Body ·
Low/Reverse Servo Low In 2nd Only ·
Intermediate Clutch ·
Valve Bodies ·
Forward Clutch Stall Speed
Application Min. Max.
3.8L engine 2,240 2,619
4.6L 2V engine 2,339 2,738
4.6L 4V MACH 1 engine 2,375 2,767 Klj . 4 ba
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DIAGNOSIS AND TESTING
Leakage Inspection
CAUTION: Do not try to stop the fluid leak by increasing the torque beyond specifications.
This may cause damage to the case threads.
Check the fluid filler tube connection at the transmission case. If leakage is found here, install a new
grommet.
Check the VSS plug or VSS sensor O-ring (model dependent). If leakage is found install a new O- ring.
Check fluid lines and fittings between the transmission and the cooler in the radiator tank for
looseness, wear, or damage. If leakage cannot be stopped by tightening a fluid tube nut, install new
parts. When fluid is found leaking between the case and cooler line fitting, check for missing or
damaged O- ring, then tighten the fitting to maximum specification.
If the leak continues, install a new cooler line fitting and tighten to specification. The same procedure
should be followed for fluid leaks between the radiator cooler and the cooler line fittings in this section;
refer to Section 307 - 02 .
Check the engine coolant in the radiator. If transmission fluid is present in the coolant, the cooler in the
radiator is probably leaking.
The cooler can be further checked for leaks by disconnecting the lines for the cooler fittings and
applying no more than 345 kPa (50 psi) air pressure to the fittings. Remove the radiator cap to relieve
the pressure buildup at the exterior of the oil cooler tank. If the cooler is leaking and or will not hold
pressure, install a new cooler.
If leakage is found at the transmission range selector lever, install a new seal.
If leakage is found at the transmission internal harness connector, install a new O- ring. 4R70W External Sealing SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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DESCRIPTION AND OPERATION
Transmission Cooling —
Integral
This vehicle with an automatic transmission is equipped with an integral transmission fluid cooler. The
cooler is contained inside of the radiator outlet tank and cannot be serviced separately. The cooler
transfers heat from the transmission fluid to the engine coolant.
For transmission fluid cooler flow test, refer to Section 307 - 01 .
For transmmission fluid cooler backflushing and cleaning, refer to Section 307 - 01 .
Transmission Fluid Cooler Tubes SECTION 307-
02: Transaxle/Transmission Cooling 2003 Mustang Workshop Manual Item Part Number Description
1 — Fluid cooler inlet tube
2 — Fluid cooler outlet tube
3 7005 Transmission case
4 — Transmission case fittings Klj . 1 ba
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DIAGNOSIS AND TESTING
Transmission Cooling
Inspection and Verification
WARNING: Never remove the radiator cap under any conditions while the engine is
operating. Failure to follow these instructions could result in personal injury and/or damage to
the cooling system or engine. To avoid having scalding hot coolant or steam blow out of the
radiator, use extreme care when removing the radiator cap from a hot radiator. Wait until the
engine has cooled, then wrap a thick cloth around the radiator cap and turn it slowly to the first
stop. Step back while the pressure is released from the cooling system. When you are certain
all the pressure has been released, press down on the radiator cap (with a cloth), turn and
remove.
The transmission fluid cooler is integral to the radiator (8005). Whenever leaks or damage to the
radiator are found, install an entire new radiator. For additional information, refer to Section 303 - 03A or
Section 303 - 03B .
Symptom Chart SECTION 307-
02: Transaxle/Transmission Cooling 2003 Mustang Workshop Manual SYMPTOM CHART
Condition
Possible Sources Action
z Transmission
Overheating z
Damaged radiator. zREPAIR or install a new
radiator. For additional
information, REFER to
Section 303 - 03A or
Section 303 - 03B .
z System leaks. zINSPECT for leaks. REPAIR
as necessary.
z Incorrect fluid level. zADJUST to proper level.
z Fluid condition. zINSPECT according to
instructions under Fluid
Condition Check. REFER to
Section 307 - 01 .
z Damaged, blocked,
reversed, leaking or
restricted cooler lines
or cooler tubes. z
INSPECT cooler lines and
tubes. REPAIR or flush as
necessary.
z Engine concerns
causing transmission
to overheat. z
INSPECT engine cooling
system. For additional
information, REFER to
Section 303 - 03A or
Section 303 - 03B .
z Excessive towing
loads. z
CHECK gross vehicle weight.
z Incorrect idle or
performance. z
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual. Klj . 1 ba
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SPECIFICATIONS
a
Manifold gauge set pressures may vary slightly depending on the distance between the service
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual General Specifications
Item Specification
A/C Compressor
Type FS-
10 swashplate, 5 double- acting pistons Displacement 170 cc (10.4 cu in)
Rotation Clockwise
A/C Pressure Relief Valve
a Open pressures 3,792-
4,137 kPa (550- 600 psi) A/C Pressure Sensor Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
Coolant Hose Lubricant
MERPOL® ESE-
M99B144- B Evaporator Core Orifice
Color Orange
Diameter 1.45 mm (0.057 in)
Magnetic Clutch
Air gap clearance 0.35-
0.75 mm (0.014- 0.030 in) Dual Function Pressure Switch (V8)
a Fan on/open 2,137-
2,344 kPa (310- 340 psi) Fan off/close 1,655-
2,137 kPa (240- 310 psi) Clutch off/open 2,999-
3,275 kPa (435- 475 psi) Clutch on/closed 1,517-
1,931 kPa (220- 280 psi) Pressure Cutoff Switch (V6)
a Open 2,999-
3,275 kPa (435- 475 psi) Close 1,586-
1,999 kPa (230- 290 psi) A/C Cycling Switch Open and Closed Pressures
a Open pressure 145-
159 kPa (21- 23 psi) Close pressure 290 kPa (42 psi)
Refrigerant Lubricant and Capacity
PAG Refrigerant Compressor Oil (R-134a Systems)
F7AZ- 19589- DA (Motorcraft YN-12- C) WSH-
M1C231- B Capacity 254 ml (8.6 oz)
Refrigerant and Capacity
R134a Refrigerant YN-
19 WSH-
M17B19- A Capacity .96 kg (34 oz)
Refrigerant System Cleaner
A/C Systems Flushing Solvent F4AZ-19579-
A — Klj . 1 ba
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Symptom Chart
Condition
Possible Sources Action
z Incorrect/erratic direction
of airflow from outlet(s) z
No vacuum to A/C heater
function switch selector.
z A/C heater function selector
switch leaks vacuum.
z Kinked/pinched vacuum hose.
z Leaking vacuum control
motor.
z Leaking A/C vacuum check
valve.
z Leaking A/C vacuum reservoir
tank and bracket.
z Vacuum actuator arm not
connected to door crank. z
Go To Pinpoint
Test A .
z Insufficient, erratic, or no
heat z
Low engine coolant level.
z Thermostat stuck open.
z Disengaged/damaged
temperature cable. z
Go To Pinpoint
Test B .
z The A/C does not
operate/does not operate
correctly z
CASS strategy failure.
z Open fuses.
z A/C clutch relay.
z Shorted blend door actuator.
z Powertrain control module.
z Circuitry short/open.
z A/C cycling switch damaged.
z A/C system discharged/low
charge.
z Function selector switch
damaged.
z A/C pressure cut-off switch
damaged.
z A/C compressor clutch
damaged. z
Go To Pinpoint
Test C .
z The A/C is always on zCircuitry short/open.
z A/C cycling switch.
z A/C heater function selector
switch.
z Constant control relay
module.
z Incorrect A/C clutch air gap. z
Go To Pinpoint
Test D .
z Insufficient A/C cooling zRestricted A/C evaporator
core orifice.
z Low refrigerant level. z
Go To Pinpoint
Test E .
z No operation in all the
temperature settings z
Damaged blend door actuator
cable.
z Damaged air temperature
control door. z
Go To Pinpoint
Test F .
z The blower motor does
not operate z
Open fuse.
z Circuitry open/shorted.
z Damaged heater blower
motor switch (18578).
z Damaged heater blower
motor switch resistor (18591).
z Damaged blower motor relay.
z Damaged blower motor. z
Go To Pinpoint
Test G .
z The blower motor
operates continuously in z
Circuitry short/open.
z Damaged heater blower z
Go To Pinpoint Klj . 6 ba
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PINPOINT TEST B: INSUFFICIENT, ERRATIC, OR NO HEAT z
Does the vacuum control motor hold a vacuum? A20 CHECK THE VACUUM CONTROL MOTOR INSTALLATION
z
Key in OFF position.
z Check the attachment of the vacuum control motor arm to
damper door.
z Is the vacuum control motor arm attached to the door or
door crank arm? Yes
REPAIR or INSTALL a
new damper door.
TEST the system for
normal operation.
No
CONNECT the vacuum
control motor arm to
the door and check
operation. TEST the
system for normal
operation.
Test Step Result / Action to Take
B1 CHECK FOR CORRECT ENGINE COOLANT LEVEL
z
Key in OFF position.
z Check the engine coolant level when hot and cold.
z Is the engine coolant at the correct level (hot/cold) as
indicated on the engine coolant recovery reservoir? Yes
GO to
B2 .
No
GO to B3 .
B2 CHECK FOR HOT WATER TO THE HEATER CORE INLET
HOSE WARNING: The heater core inlet hose will become
too hot to handle and may cause serious burns if the
system is working correctly.
z Key in START position.
z Allow the engine to reach normal operating temperature.
z Feel the heater core inlet hose. Yes
GO to
B4 .
No
TEST the engine cooling
system for correct
operation. REFER to
Section 303 - 03A or
Section 303 - 03B . Klj . 14 ba
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Heater Core
WARNING: Carbon monoxide gas is colorless, odorless and dangerous. If it is necessary
to operate the engine with the vehicle in a closed area such as a garage, always use an exhaust
collector to vent the exhaust gases outside the closed area. Failure to follow these instructions
may result in personal injury.
1. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are
good and did not require installation of a new heater core. If a heater core leak is suspected, the
heater core must be tested by following the Plugged Heater Core Component Test before the
Heater Core Pressure Test. Carry out a system inspection by checking the heater system
thoroughly as follows:
Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A
coolant leak in the heater water hose could follow the heater core tube to the heater core and
appear as a leak in the heater core.
CAUTION: Spring- type clamps are installed as original equipment. Installation and
overtightening of non- specification clamps can cause leakage at the heater water hose
connection and damage the heater core.
2. Check the integrity of the heater water hose clamps.
Heater Core— Plugged
WARNING: The heater core inlet hose will become too hot to handle if the system is
working correctly.
1. Check to see that the engine coolant is at the correct level.
2. Start the engine and turn on the heater.
3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot.
If it is not hot:
zthe heater core may have an air pocket.
z the heater core may be plugged.
z the thermostat is not working correctly.
Heater Core— Pressure Test
Use the radiator/heater core pressure tester to carry out the pressure test. 1. NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
Drain the coolant from the cooling system. For additional information, refer to Section 303 - 03A
or
Section 303 - 03B .
2. Disconnect the heater water hoses from the heater core. For additional information, refer to Klj . 37 ba
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Section 412 - 02 .
3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube.
4. Fill the heater core and heater water hoses with water and install Plug BT-7422- B and adapter
BT- 7422- A from the radiator/heater core pressure tester in the heater water hose ends. Secure
the heater water hoses, plug and adapter with hose clamps.
5. Attach the pump and gauge assembly from the radiator/heater core pressure tester to the adapter.
6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core.
7. Observe the pressure gauge for a minimum of three minutes.
8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the
bench test.
Heater Core— Bench Test
1. Remove the heater core from the vehicle. For additional information, refer to Section 412 - 02 .
2. Drain all of the coolant from the heater core.
3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter.
4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water.
5. If a leak is observed, install a new heater core. Klj . 38 ba
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GENERAL PROCEDURES
Air Conditioning (A/C) System Check —
Retail Procedure
NOTE: This Retail Procedure is not eligible for claiming on Ford paid repairs (warranty and ESP).
NOTE: The engine should be run at idle for 10 minutes with the air conditioning on and set to MAX A/C
before carrying out this retail procedure.
NOTE: Read and follow all of the Warnings, Cautions and Notes at the beginning of this section before
continuing.
1. Visual inspection
Open the hood and visually inspect the heating and air conditioning systems for the following:
zCoolant reservoir for correct coolant level
z Heater hoses for deterioration or loose connections
z Radiator and condenser for debris or damaged fins restricting airflow, loose mounting or
connections
z Accessory drive belt(s) and cooling fan(s) for wear or physical damage
z Refrigerant lines and connections for physical damage or loose connections
z Compressor for physical damage or loose connections
z Suction accumulator/drier for physical damage or loose connections
z Wiring and connectors for excessive wear, loose or damaged connections, or incorrect
routing
2. A/C refrigerant analysis
zCarry out air conditioning refrigerant analysis. For additional information, refer to
Refrigerant Identification Testing in this section.
z If the refrigerant fails the analysis, discontinue diagnosis and make recommendations for
repairs.
z If the refrigerant passes the analysis, carry out the air conditioning system check.
3. Air conditioning system check
zConnect manifold gauge set or charging station with gauges to refrigerant system.
z With the vehicle in park, parking brake set, thermometer installed in center panel vent,
and air conditioning system on and set to MAX A/C, start the engine.
z Record air refrigerant system pressures while running the engine at 1,500 rpm and allow
engine to return to idle.
z Operate the blower motor in all control positions and check for correct blower speed
changes.
z With the blower motor on HI, operate air discharge mode selector in all positions and
check for correct airflow in each position.
z Operate the temperature blend selector in all positions and check for correct change in
discharge temperature. Check the air discharge temperature with the selector in the
coolest position and the air conditioning on and set to MAX A/C to determine if the air
discharge temperature is acceptable for the current ambient air temperature.
z Carry out the EATC self- test (if applicable).
If the refrigerant system pressures were low, carry out the refrigerant system leak test.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Klj . 1 ba
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