tow FORD MUSTANG 2003 User Guide

GENERAL PROCEDURES
Exhaust System Neutralizing
WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and
potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an
enclosed area.
WARNING: Exhaust system components are hot.
NOTE: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to
transmit vibration as if grounded.
1. WARNING: The electrical power to the air suspension system must be shut off prior
to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by
turning off the air suspension switch. Failure to do so can result in unexpected inflation
or deflation of the air springs, which can result in shifting of the vehicle during these
operations.
CAUTION: Make sure the system is warmed up to normal operating temperature, as
thermal expansion can be the cause of a strain problem.
Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last).
zVerify there is adequate clearance to prevent grounding at any point in the system. Make
sure that the catalytic converter and heat shield do not contact the frame rails.
z After neutralization, the rubber in the exhaust hangers should show some flexibility when
movement is applied to the exhaust system.
z With the exhaust system installed securely and cooled, the rear hanger should be angled
forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.
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GENERAL PROCEDURES
Wheel Bearing Check
1. WARNING: The electrical power to the air suspension system must be shut off prior
to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by
turning off the air suspension switch. Failure to do so can result in unexpected inflation
or deflation of the air springs, which can result in shifting of the vehicle during these
operations.
Raise the vehicle until the front tires are off the floor.
zMake sure the wheels are in a straight forward position.
2. NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to
allow free movement of the tire and wheel assembly.
Spin the tire by hand to check the wheel bearings for roughness.
3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following:
1. On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary.
2. On vehicles with one sealed bearing, install a new wheel hub.
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GENERAL PROCEDURES
Camber and Caster Adjustment —
Front
All vehicles 1. Remove the rivet. Loosen the nuts and bolt.
Vehicles requiring camber adjustment 2. Move the front suspension camber adjusting plate (3B391) to the required camber setting.
Vehicles requiring caster adjustment 3. NOTE: If caster adjustment is necessary to resolve a pull, or out of specification cross- caster
split, then slotting the shock tower at the front shock absorber (18124) upper mounting point is
an acceptable method. This procedure should not be routinely performed with all alignments
and only after all other possible sources have been inspected and corrected as necessary.
Determine the amount of caster adjustment needed.
zIf no more than 0.6 degree is needed, only one shock tower needs to be slotted.
4. Mark the camber position of the front suspension camber adjusting plate (3B391).
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5. Remove the nuts, bolt and the front suspension camber adjusting plate.
6. Raise the front end. Position the strut and spring assembly out of the way. For additional
information, refer to Section 100 - 02 .
7. Cut slots perpendicular to the existing camber adjustment slots. zMoving the top of the front shock absorber toward the rear of the vehicle will increase the
caster reading for that side.
z Each millimeter of adjustment should yield approximately 0.12 degree of caster change.
z Do not cut slots any longer than 5 mm (0.2 in.) in any direction.
z Remove any burrs.
z Clean and paint any exposed metal.
8. Position the strut and spring assembly. Lower the front end.
9. Install the front suspension camber adjustment plate, bolt and nuts. Hand tighten the bolt and nuts. Klj . 2 ba
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All vehicles
1. NOTE: Inspect the insulators for wear or damage. Install new insulators if necessary.
Install the upper insulator on the spring.
2. Install the lower insulator on the lower arm.
3. Install the rear spring. Make sure the pigtail on the lower arm is at the rear of the vehicle and pointing toward the left side of the vehicle.
4. Install the pivot bolt. 1. Carefully raise the lower arm into position with the special tool 014- 00942.
2. Install a new pivot bolt and nut. Do not tighten at this time. Klj . 3 ba
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4. Install a differential bearing shim on the left side.
5.
CAUTION: Always install the bearing caps in their identical locations and positions.
NOTE: Apply pressure toward the left side to make sure the left differential bearing cup seats
correctly.
Install the left bearing cap and loosely install the bolts.
6. Install progressively larger differential bearing shims on the right side until the largest shim selected is installed by hand. Klj . 7 ba
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4. Install a differential bearing shim on the left side.
5.
CAUTION: Always install the bearing caps in their identical locations and positions.
NOTE: Apply pressure toward the left side to make sure the left differential bearing cup seats
correctly.
Install the left bearing cap and loosely install the bolts.
6. Install progressively larger differential bearing shims on the right side until the largest shim selected is installed by hand. Klj . 7 ba
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23.
NOTE: Apply pressure toward the left side to fully seat the differential bearing cup.
Install progressively larger differential bearing shims on the RH side until the largest differential
bearing shim selected can be assembled with a slight drag feel.
24. Install the RH differential bearing cap. zTighten both bearing caps to specification.
25. Rotate the differential assembly to make sure it turns freely. Klj . 10 ba
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PINPOINT TEST G: HYDRO-
BOOST BRAKE SYSTEM OPERATION
SUSPECT connections between the power steering pump reservoir and
between the power steering pump reservoir and the hydro-
boost
power brake booster.
z Are there any obstructions? REMOVE
obstructions or
INSTALL a new
hose.
No
GO to
F2 .
F2 CHECK BOOSTER OPERATION
z
Have an assistant check the fluid in the power steering pump
reservoir while rapidly applying the brake pedal approximately one
inch.
z Does the fluid show any movement or spouting? Yes
System OK.
No
INSTALL a new
hydro-boost
assembly. Test Step Result / Action to Take
G1 CHECK BASIC OPERATION
z
Key in OFF position.
z Press and release brake pedal several times to deplete all
hydraulic pressure from the hydro- boost power brake
booster.
z Press and hold brake pedal with light pressure.
z Key in START position.
z Does the brake pedal fall slightly and hold, and is less
pressure now required to hold brake pedal at the new
position? Yes
Hydro-
boost is OK.
No
GO to G2 .
G2 CHECK FOR HYDRAULIC BRAKE LEAK
z
With engine running, press and release brake pedal several
times.
z Hold brake pedal down with medium pressure, 34- 47 Nm
(25- 35 lb- ft).
z Does brake pedal move toward floor? Yes
GO to
G3 .
No
GO to G4 .
G3 CHECK FOR LEAKS —
BRAKE FLUID LINES z
Check for leaks at brake lines, including brake master
cylinder and brake hose.
z Do components check OK? Yes
COMPLETE master cylinder
By-
Pass Condition Test in
this section.
No
INSTALL new hoses and
lines as necessary. G4 CHECK HYDRO-
BOOST CONNECTIONS z
Clean the hydro- boost power brake booster, power steering
pressure hose, power steering gear pressure hose and
power steering return hose and connection.
z Start engine and run at idle.
z Check hose connections for leakage.
z Do hose connections check OK? Yes
GO to
G5 .
No
REPAIR or INSTALL new
hose and connections as
necessary. G5 CHECK FOR HYDRO-
BOOST LEAK Klj . 12 ba
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11. Remove the snap ring.
12. Remove the upper bearing spring (3520).
13. Remove the bearing sleeve (3518).
14. Remove the lower bearing tolerance ring (3L539).
1. Slide the steering column shaft in toward the lock cylinder housing (3511).
2. Slide the steering column bearing tolerance ring from the steering column shaft and remove the shaft. Klj . 4 ba
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