pinpoint FORD MUSTANG 2003 User Guide

acceleration from a slow
speed or stop
assembly
mispositioned. and the rear suspension
for damage or wear.
REPAIR as necessary.
z Incorrect or high
CV joint
operating angle. z
CHECK vehicle ride
height is within limits.
REPAIR as necessary.
z Damaged or
worn front
suspension
components. z
CHECK for a loose
stabilizer bar, damaged
or loose strut/strut
bushings or loose or
worn ball joints.
INSPECT the steering
linkage for wear or
damage. REPAIR or
INSTALL new
components as
necessary.
z Shimmy—most
noticeable on
coast/deceleration. Also
hard steering condition z
Excessive
positive caster. z
CHECK the caster
alignment angle.
CORRECT as
necessary. REFER to
Section 204 - 00 .
Symptom Chart—
Tire Noise/Vibration Condition
Possible Sources Action
z Tire noise— hum/moan
at constant speeds z
Abnormal wear
patterns. z
SPIN the tire and CHECK
for tire wear. INSTALL a
new tire as necessary.
INSPECT for
damaged/worn suspension
components. CARRY OUT
wheel alignment.
z Tire noise— noise tone
lowers as the vehicle
speed is lowered z
Out-of- balance
tire. z
BALANCE the tire and
road test. INSTALL a new
tire as necessary. REFER
to Section 204 - 04 .
z Tire noise — ticking
noise, changes with
speed z
Nail puncture or
stone in tire
tread. z
INSPECT the tire. REPAIR
as necessary.
z Wheel and tire—
vibration and noise
concern is directly
related to vehicle
speed and is not
affected by
acceleration, coasting
or decelerating z
Damaged or
worn tire. z
Go To Pinpoint Test J .
z Tire wobble or
shudder — occurs at
lower speeds z
Damaged wheel
bearings. z
SPIN the tire and CHECK
for abnormal wheel
bearing play or roughness.
ADJUST or INSTALL new
wheel bearings as
necessary. REFER to
Section 204 - 01 .
z Damaged wheel. zINSPECT the wheel for
damage. INSTALL a new
wheel as necessary.
REFER to Section 204 -Klj . 38 ba
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01 .
z Damaged or
worn suspension
components. z
INSPECT the suspension
components for wear or
damage. REPAIR as
necessary.
z Loose wheel
nuts. z
CHECK the wheel nuts.
TIGHTEN to specification.
REFER to Section 204 -
04 .
z Damaged or
uneven tire wear. z
SPIN the tire and CHECK
for abnormal tire wear or
damage. INSTALL a new
tire as necessary. REFER
to Section 204 - 04 .
z Tire shimmy or
shake— occurs at
lower speeds z
Wheel/tire out of
balance. z
BALANCE the wheel/tire
assembly.
z Uneven tire wear. zCHECK for abnormal tire
wear. INSTALL a new tire
as necessary. REFER to
Section 204 - 04 .
z Excessive radial
runout of wheel
or tire. z
CARRY OUT a radial
runout test of the wheel
and tire. INSTALL a new
tire as necessary. REFER
to Section 204 - 04 .
z Worn or
damaged wheel
studs or
elongated stud
holes. z
INSPECT the wheel studs
and wheels. INSTALL new
components as necessary.
REFER to Section 204 - 01
for the front wheels or
Section 204
- 02 for the rear
wheels.
z Excessive lateral
runout of the
wheel or tire. z
CARRY OUT a lateral
runout test of the wheel
and tire. CHECK the
wheel, tire and hub.
REPAIR or INSTALL new
components as necessary.
z Foreign material
between the
brake disc and
hub or in the
brake disc fins. z
CLEAN the mounting
surfaces of the brake disc
and hub. CHECK the
brake disc fins for material.
z High speed shake or
shimmy—occurs at
high speeds z
Excessive wheel
hub runout.
z Damaged or
worn tires.
z Damaged or
worn wheel
bearings.
z Worn or
damaged
suspension or
steering linkage
components.
z Brake disc or
drum imbalance. z
Go To Pinpoint Test K . Klj . 39 ba
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Section 308 - 02 .
z Grease or oil on the
clutch disc facing. z
CHECK the input shaft
seal and rear main oil
seal. REPAIR as
necessary. INSTALL a
new clutch disc.
REFER to Section 308 -
03A for T50D
transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Clutch disc surface
glazed or damaged. z
INSPECT the clutch
disc surface for a
glazed, hardened or
damage condition.
CARRY OUT a disc
check. INSTALL a new
clutch disc as
necessary. REFER to
Section 308 - 01 .
z Damaged or worn
clutch pressure
plate. z
INSPECT the clutch
pressure plate for wear
or damage. INSTALL a
new clutch pressure
plate as necessary.
REFER to Section 308 -
01 .
z Flywheel surface
damaged or glazed. z
INSPECT the flywheel
for damage or wear.
CARRY OUT a
flywheel runout check.
INSTALL a new
flywheel as necessary.
REFER to Section 303 -
01A for 3.8L engines or
Section 303 - 01B for
4.6L (2V) engines.
z Clutch chatter noise—
noise when clutch
pedal is released at
initial take- off. Clutch is
hard to engage and
disengage z
Pilot bearing worn,
damaged or not
correctly aligned in
bore. z
INSPECT the clutch
pressure plate release
fingers for uneven
wear, clutch
components burnt or a
seized pilot bearing.
INSTALL a new pilot
bearing as necessary.
REFER to Section 308 -
01 .
z Clutch vibration zLoose flywheel
bolts.
z Damaged or loose
clutch pressure
plate.
z Excessive flywheel
runout. z
Go To Pinpoint Test L .
z Transmission
rattling/clattering
noise— noise at idle or
on light acceleration
from a stop. Gear
selection difficult z
Gearshift lever joint
worn or damaged. z
INSTALL a new
gearshift lever. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions. Klj . 41 ba
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information, REFER to
Section 205
- 00 .
REPAIR as necessary.
z Transmission
rumble/growl— noise at
all speeds in forward
gears, more
pronounced in a heavy
acceleration condition z
Damaged or worn
transmission
bearing or gears
(high mileage
vehicles). z
CHECK transmission
fluid for excessive
metal particles.
REPAIR as necessary.
REFER to Section 308 -
03A for T50D
transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transfer case whine—
noise at all ranges z
Incorrect fluid level
or fluid quality. z
CHECK that the
transfer case is filled to
the correct level and
with the specified fluid.
REFER to Section 308 -
03A for T50D
transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Worn oil pump. zDISASSEMBLE the
transfer case. CHECK
the oil pump for wear or
damage. REPAIR as
necessary.
z Under- inflated or
oversized tires. z
CONFIRM that the tires
and wheels are correct
for the vehicle. CHECK
that the tire inflation
pressures are correct.
z Transfer case
growl/rumble— noise at
all ranges (A small
amount of planetary
noise can be heard
when the transfer case
is operated in low
range.) z
Damaged or worn
bearings or
planetary gear. z
DISASSEMBLE the
transfer case. CHECK
the bearings or
planetary gear for wear
or damage. REPAIR as
necessary.
z Transfer case
scraping/grating—
noise at all ranges z
Excessively
stretched drive
chain hitting the
case. z
DISASSEMBLE the
transfer case. CHECK
the drive chain for wear
or damage. REPAIR as
necessary.
z Transfer case
howl/hum— noise at all
ranges or high range
only z
Worn or damaged
sun (input) gear,
clutch pack
(intermediate) gear
or output shaft gear. z
DISASSEMBLE the
transfer case. CHECK
the gears for wear or
damage. REPAIR as
necessary.
z Transfer case
howl/hum— noise at
low range only z
Worn or damaged
intermediate gear
and sliding gears
(clutch pack). z
DISASSEMBLE the
transfer case. CHECK
the gears for wear or
damage. REPAIR as
necessary.
z Transfer case
vibration— vibration felt
with vehicle in 4WD z
Transfer case
mounting.
z Driveshaft out of
balance.
z Excessive pinion z
Go To Pinpoint Test M . Klj . 44 ba
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Pinpoint Tests
The pinpoint tests are a step-by-
step diagnostic process designed to determine the cause of a z
Bump—occurs
when shifting
from PARK to
a drive or
reverse
position.
Similar to
Clunk but with
no sound z
Initial gear
engagement. z
Acceptable condition.
z Buzz or hiss zIncorrect driveline
angles. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to Section 205 - 00 .
z Worn or damaged
main control
solenoids or valves. z
Using a transmission tester,
ACTIVATE the solenoids to
duplicate sound. INSTALL
new components as
necessary. REFER to Section 307 - 01 .
z Vibration— a
high frequency
(20–80 Hz) that
is felt through
the seat or
gear shifter.
Changes with
engine speed z
Transmission cooler
lines grounded out. z
CHECK the transmission
cooler lines. REPAIR as
necessary.
z Flexplate to torque
converter nuts loose. z
CHECK the flexplate nuts.
TIGHTEN to specification.
REFER to Section 307 - 01 .
z Fluid filler tube
grounded out. z
CHECK the fluid filler tube.
REPAIR as necessary.
z Shift cable incorrectly
routed, grounded out
or loose. z
CHECK the shift cable.
REPAIR as necessary.
Section 307 - 05 .
z Shutter or
chatter—
occurs with
light to medium
acceleration
from low
speeds or a
stop z
Electrical
inputs/outputs.
z Vehicle wiring
harness.
z Incorrect
inputs/outputs from
the powertrain control
module (PCM), digital
transmission range
(TR) sensor, brake
pedal position (BPP)
sensor, throttle
position (TP) sensor,
transmission speed
sensor (TSS), output
speed shaft (OSS)
sensor or the torque
converter clutch
(TCC). z
CARRY OUT a Torque
Converter Clutch Operation
Test. RUN on- board
diagnostics or self- test.
REFER to Section 307 - 01 .
CLEAR the DTC's, ROAD
TEST and RERUN on- board
diagnostics or self- test. Klj . 47 ba
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condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the
steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is
necessary to remove various vehicle components to gain access to the component requiring testing.
Reinstall all components after verifying system operation is normal.
PINPOINT TEST A: BRAKE VIBRATION/SHUDDER
Test Step Result / Action to Take
A1 ROAD TEST THE VEHICLE—
LIGHT BRAKING z
Check that the wheel and tires are correct for the vehicle.
Inspect the tires for abnormal wear patterns.
z Road test the vehicle. Warm the brakes by slowing the vehicle
a few times from 80– 32 km/h (50 to 20 mph) using light braking
applications. At highway speeds of 89–97 km/h (55- 60 mph),
apply the brake using a light pedal force.
z Is there a vibration/shudder felt in the steering wheel, seat
or brake pedal? Yes
GO to
A4 .
No
GO to A2 .
A2 ROAD TEST THE VEHICLE—
MODERATE TO HEAVY
BRAKING z
Road test the vehicle. At highway speeds of 89–97 km/h (55- 60
mph), apply the brake using a moderate to heavy pedal force.
z Is there a vibration/shudder? Yes
For vehicles with ABS,
GO to
A3 . For vehicles
with standard brakes,
GO to A4 .
No
Vehicle is OK. VERIFY
condition with customer.
TEST the vehicle for
normal operation. A3 NORMAL ACTUATION OF THE ABS SYSTEM DIAGNOSIS
z
During moderate to heavy braking, noise from the hydraulic
control unit (HCU) and pulsation in the brake pedal can be
observed. Pedal pulsation coupled with noise during heavy
braking or on loose gravel, bumps, wet or snowy surfaces is
acceptable and indicates correct functioning of the ABS
system. Pedal pulsation or steering wheel nibble, (frequency is
proportioned to the vehicle speed) indicates a concern with a
brake or suspension component.
z Is the vibration/shudder vehicle speed sensitive? Yes
GO to
A5 .
No
The brake system is
operating correctly. A4 APPLICATION OF THE PARKING BRAKE
z
NOTE: Begin at the front of the vehicle unless the vibration or
shudder has been isolated to the rear.
z This test is not applicable to vehicles with drum- in-hat type
parking brakes. For vehicles with drum- in-hat parking brakes,
proceed to the next test. For all other vehicles, apply the
parking brake to identify if the problem is in the front or rear
brake. At highway speeds of 89–97 km/h (55- 60 mph), lightly
apply the parking brake until the vehicle slows down. Release
the parking brake immediately after the test.
z Is there a vibration/shudder? Yes
GO to
A7 .
No
GO to A5 .
A5 CHECK THE FRONT WHEEL BEARINGS
z
Check the front wheel bearings. Refer to Wheel Bearing Check in this section.
z Are the wheel bearings OK? Yes
GO to
A6 . Klj . 48 ba
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PINPOINT TEST B: ENGINE TICKING NOISE No
INSPECT the wheel
bearings. ADJUST or
REPAIR as necessary.
TEST the system for
normal operation.
A6 CHECK THE FRONT SUSPENSION
z
Check the front suspension for:
zBroken or loose bolts.
z Damaged springs.
z Worn or damaged upper and lower control arm
bushings.
z Loose or rough front bearings.
z Uneven tire wear.
z Are all the suspension components in satisfactory
condition? Yes
GO to
A7 .
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation. A7 RESURFACE THE FRONT BRAKE DISCS
z
CAUTION: Do not use a bench lathe to machine brake
discs.
z NOTE: Follow the manufacturer's instructions to machine the
brake discs. After machining, make sure the brake disc meets
the thickness specification.
z Refer to Brake Disc Machining in this section. Resurface the
front brake discs. Road test the vehicle.
z Is the vibration/shudder present? Yes
GO to
A8 .
No
Vehicle is OK. A8 CHECK THE REAR SUSPENSION
z
Check the rear suspension for:
zBroken or loose bolts.
z Damaged or worn springs or spring bushings.
z Worn or damaged upper and lower control arm
bushings.
z Worn or damaged trailing arms.
z Loose or rough rear bearings.
z Uneven tire wear.
z Are all the suspension components in satisfactory
condition? Yes
GO to
A9 .
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation. A9 RESURFACE THE REAR BRAKE DISC OR DRUM
z
CAUTION: Do not use a bench lathe to machine brake
discs.
z NOTE: Follow the manufacturers instructions to machine the
brake discs. After machining, make sure the brake disc meets
the thickness specification.
z Refer to Brake Disc Machining in this section. Resurface the
rear brake discs or drums. Road test the vehicle.
z Is the vibration/shudder present? Yes
CHECK the front
suspension for wear or
damage. RESURFACE
the front brake discs.
TEST the system for
normal operation.
No
Vehicle is OK.
Test Step Result / Action to Take
B1 CHECK FOR TICKING NOISE AT THE FUEL
RAIL z
Disconnect the first fuel line clip. Yes Klj . 49 ba
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PINPOINT TEST C: ACCESSORY DRIVE BEARING HOOT
PINPOINT TEST D: POWER STEERING MOAN
PINPOINT TEST E: ENGINE DRIVEN COOLING FAN MOAN operating correctly?
No
INSTALL a new valve lifter/lash adjuster
(s). TEST the system for normal
operation.
Test Step Result / Action to Take
C1 CHECK THE IDLER AND TENSIONER
PULLEY BEARINGS z
Carry out the Vehicle Cold Soak
Procedure in this section.
z Key in START position.
z Place an EngineEAR probe directly on the
pulley center post or bolt to verify which
bearing is making the noise.
z Key in OFF position.
z Is either bearing making the noise? Yes
INSTALL a new pulley/idler. CARRY OUT the
Vehicle Cold Soak Procedure and TEST the
system for normal operation.
No
CONDUCT a diagnosis on other suspect
accessory drive components.
Test Step Result / Action to Take
D1 CHECK THE POWER STEERING
SYSTEM z
Carry out the Vehicle Cold Soak
Procedure in this section.
z Key in START position.
z Turn the steering wheel while the noise
is occurring and listen for changes in
sound pitch or loudness.
z Key in OFF position.
z Does the sound pitch or loudness
change while turning the steering
wheel? Yes
GO to
D2 .
No
CONDUCT a diagnosis on other suspect
accessory drive components. D2 VERIFY THE SOURCE
z
Key in START position.
z Place an EngineEAR probe near the
power steering pump/reservoir while the
noise is occurring. While an assistant
turns the steering wheel, listen for
changes in sound pitch or loudness.
z Key in OFF position.
z Does the sound pitch or loudness
change while turning the steering
wheel? Yes
VERIFY that the supply tube to the pump is
unobstructed. CHECK the fluid condition and
level. DRAIN the fluid and REFILL. CARRY
OUT the Vehicle Cold Soak Procedure and
TEST the system for normal operation. REFER
to Section 211
- 02 .
No
Normal system operation. Test Step Result / Action to Take
E1 CHECK THE ENGINE DRIVEN COOLING
FAN AFTER A COLD SOAK Klj . 51 ba
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PINPOINT TEST F: DRUMMING NOISE z
Carry out the Vehicle Cold Soak Procedure
in this section.
z Key in START position.
z Assess the airflow.
z Raise the engine speed to 1500 rpm while
listening for the moan to increase in
proportion to the airflow.
z Key in OFF position.
z Does the moan increase in proportion to
the airflow? Yes
TEST the fan for normal operation. If the
fan tests normal, GO to
E2 . Otherwise,
REPAIR as necessary.
No
Normal system operation. E2 CHECK THE ENGINE DRIVEN COOLING
FAN AT NORMAL OPERATING TEMPERATURE z
Key in START position.
z Run the engine to normal operating
temperature while listening for the moan to
stop.
z Key in OFF position.
z Does the moan stop? Yes
Normal clutch operation.
No
INSTALL a new fan clutch. TEST the
system for normal operation.
Test Step Result / Action to Take
F1 CHECK THE EXHAUST SYSTEM
z
Key in START position.
z Increase the engine rpm until the noise is the loudest. Note
the engine rpm.
z Key in OFF position.
z Add approximately 9 kg (20 lb) of weight to the exhaust
system. First place the weight at the tail pipe and test, then
at the front pipe.
z Key in START position.
z Increase the engine rpm and listen for the drumming noise.
Note the engine rpm if the noise occurs.
z Key in OFF position.
z Using a vibration analyzer (VA), determine the amount of
vibration that occurs with the drumming noise.
z Is the noise/vibration reduced or eliminated, or does the
noise/vibration occur at a different rpm? Yes
CARRY OUT
Exhaust System Neutralizing in this
section. TEST the system
for normal operation.
No
GO to F2 .
F2 POWERTRAIN/DRIVETRAIN MOUNT NEUTRALIZING
z
Carry out Powertrain/Drivetrain Mount Neutralizing in this
section. Test the system for normal operation.
z Is the noise reduced or eliminated? Yes
Vehicle OK. TEST the
system for normal
operation.
No Klj . 52 ba
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PINPOINT TEST G: ENGINE TICKING, KNOCKING OR CONTINUOUS
RATTLE
PINPOINT TEST H: FRONT SUSPENSION NOISE CONDUCT diagnosis of
other suspect components.
Test Step Result / Action to Take
G1 CHECK FOR NOISE AT THE VALVE COVERS
AND THE FRONT COVERS (OHC ENGINES) z
Carry out the Vehicle Cold Soak Procedure in
this section.
z Key in START position.
z NOTE: For a short- duration ticking noise,
multiple engine starts may be necessary.
z Using an EngineEAR, listen closely at the valve
covers and the front covers (OHC engines) by
placing the probe near the surface of the valve
cover and then on the surface front cover.
z Key in OFF position.
z Is the noise source apparent? Yes
REMOVE the appropriate cover and
INSPECT for loose, worn/broken
components. REPAIR as necessary.
TEST the system for normal operation.
No
GO to
G2 .
G2 CHECK FOR NOISE AT THE CYLINDER
BLOCK z
Key in START position.
z Using an EngineEAR, listen closely at the
cylinder block by placing a probe on or near
each freeze plug.
z Key in OFF position.
z Is the noise source apparent? Yes
REPAIR or INSTALL new components
as necessary.
No
GO to
G3 .
G3 CHECK FOR NOISE WHILE DISCONNECTING
EACH FUEL INJECTOR ELECTRICAL
CONNECTOR, ONE AT A TIME z
Key in START position.
z Disconnect each fuel injector electrical
connector, one at a time, to decrease piston
force and listen for the noise.
z Key in OFF position.
z Is the noise reduced or eliminated? Yes
INSTALL a new fuel injector. TEST the
system for normal operation.
No
INSPECT accessory drive system or the
transmission as a possible source.
Test Step Result / Action to Take
H1 ROAD TEST THE VEHICLE
z
Test drive the vehicle.
z NOTE: An assistant will be needed for this road test.
z During the road test, drive the vehicle over a rough road.
Using ChassisEARs, determine from which
area/component the noise is originating.
z Is there a squeak, creak or rattle noise? Yes
GO to
H2 .
No
The suspension system is
OK. CONDUCT a diagnosis
on other suspect systems. H2 INSPECT THE STEERING SYSTEM
Yes Klj . 53 ba
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