steering FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Release Cable —
Clutch
Removal
CAUTION: Whenever the clutch release lever cable (7K553) is disconnected for any
reason, such as transmission removal, clutch pedal components or clutch release lever cable
replacement, it is imperative the correct method for installing the clutch release lever cable be
followed. Incorrect installation may damage components or cause system failure.
1. Remove the instrument panel steering column cover. 1. Remove the screws.
2. Remove the instrument panel steering column cover.
2. Remove the instrument panel reinforcement. 1. Remove the screws.
2. Remove the instrument panel reinforcement.
3. Lift the clutch pedal (7519) to its most upward position.
SECTION 308-
02: Clutch Controls 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Speed Control
Refer to Wiring Diagrams Cell
31 , Speed Control for schematic and connector information.
Principles of Operation
The speed control system is designed to maintain vehicle speed above 48 km/h (30 mph). After the
ON switch is depressed, depressing the SET/ACCEL switch will activate the speed control servo. To
increase a set speed, either depress and hold for continuous acceleration, or momentarily tap the
SET/ACCEL switch for 1.6 km/h (1 mph) acceleration increments. To decrease a set speed, depress
and hold the COAST switch until the target speed is reached, or momentarily tap the COAST switch
for 1.6 km/h (1 mph) deceleration increments. When the speed control system has been disabled by
tapping the brake pedal, the RESUME switch can be depressed and the vehicle will return to the
original set speed if the vehicle is traveling over 48 km/h (30 mph) and the OFF switch has not been
depressed.
NOTE: The deactivator switch is provided as an additional safety feature. Normally, when the brake
pedal is depressed, an electrical signal from the brake lamp circuit to the speed control servo will
deactivate the system. Under increased brake pedal effort, the deactivator switch will open and
remove power to the speed control servo, releasing the throttle independent of the speed control
servo.
NOTE: The air bag sliding contract provides the electrical interface between the steering column wiring
and the speed control actuator switches in the steering wheel.
The inputs to the speed control servo are the:
zvehicle speed signal.
SECTION 310-
03: Speed Control 2003 Mustang Workshop Manual Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent
diagnostic tool 73 Digital Multimeter or
equivalent
105-
R0051 Breakout Box, EEC-V Control
System 418-049, or equivalent
014- 00950 Klj . 1 ba
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REMOVAL AND INSTALLATION
Switch —
Speed Control Actuator
Removal 1. Remove the steering wheel; refer to Section 211 - 04 .
2. Remove the steering wheel rear cover. 1. Remove the screws.
2. Remove the steering wheel rear cover.
3. Remove the ribbon harness from the clips.
4. Remove the horn contact electrical connectors.
5. Remove the right side horn contact. 1. Remove the screws. 2. Remove the contact. SECTION 310-
03: Speed Control 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 412-
01: Air Distribution and Filtering 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
in Steering column reinforcement 9 80
Instrument panel steering column cover bolts 9 80
Duct RH instrument panel register 9 80 Klj . 1 ba
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REMOVAL AND INSTALLATION
Register —
LH
Removal 1. Remove the instrument panel steering column cover bolts.
2. Unsnap and remove the instrument panel steering column cover.
3. Remove the bolts and the steering column reinforcement. 4. Remove the screws. SECTION 412-
01: Air Distribution and Filtering 2003 Mustang Workshop Manual Klj . 1 ba
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The boost pressure gauge on the instrument cluster receives and measures the boost pressure
directly from the intake manifold. The boost pressure gauge will display between 0.0-
0.48 kpa (0.0-10
psi) boost pressure dependent upon accelerator position, engine load, and engine rpm.
LOW FUEL Level Indicator
The low fuel level indicator is hardwired from the fuel sender to the instrument cluster. The instrument
cluster will illuminate the low fuel indicator when the usable fuel quantity is less than 1/8 tank (15%) of
fuel tank capacity.
Oil Pressure Gauge
The oil pressure gauge is hardwired from the oil pressure switch to the instrument cluster. The oil
pressure gauge will indicate either normal or no oil pressure.
CHECK FUEL CAP
The CHECK FUEL CAP indicator is used to indicate significant leaks in the fuel tank evaporative
system due to a loose fuel cap. Fuel tank pressure is monitored by the PCM. If a leak is detected the
PCM signals a fault to the instrument cluster via the SCP network. Once the PCM has detected a
loose fuel cap and the CHECK FUEL CAP indicator is illuminated, the indicator will remain illuminated
until the fuel cap is secured and the vehicle has been running for several minutes. For additional
information, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
BRAKE Warning Indicator
The BRAKE warning indicator activates when the generic electronic module (GEM) detects the ignition
switch circuits are in the RUN state, when the GEM detects low brake fluid level, or that the parking
brake is applied. The BRAKE warning indicator will prove out starting when the GEM detects that the
ignition circuits have made a transition to RUN or START from OFF, ACC, or keyout and ending when
either three seconds have elapsed or when the GEM detects the ignition circuits have made a
transition to OFF, ACC, or keyout.
Safety Belt Warning Indicator
The safety belt switch is hardwired to the GEM. The safety belt warning indicator will be illuminated
when the GEM sends a ground signal to the instrument cluster.
ABS Warning Indicator
The ABS warning indicator will be illuminated when the anti- lock brake control module sends a ground
signal to the instrument cluster. The prove- out of the ABS indicator is controlled by the anti- lock brake
control module.
SERVICE ENGINE SOON Indicator
The SERVICE ENGINE SOON indicator receives its signal from the PCM over the SCP network. If the
instrument cluster does not receive a message from the PCM within five seconds, the instrument
cluster will illuminate the SERVICE ENGINE SOON indicator and log a diagnostic trouble code (DTC).
High Beam Indicator
The high beam indicator will illuminate when the steering column multifunction switch is in the high
beam position by sending a battery signal to the instrument cluster. Right and Left Turn Indicator Klj . 3 ba
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The right and left turn indicators will illuminate when the steering column multifunction switch is in
either turn signal position or hazard lamps position by sending a battery signal to the instrument
cluster.
AIR BAG Warning Indicator
The AIR BAG warning indicator will be illuminated when the restraint control module (RCM) sends a
ground signal to the instrument cluster. The prove-
out of the AIR BAG warning indicator is controlled
by the RCM.
THEFT Indicator
The THEFT indicator provides a passive anti- theft system (PATS) prove-out. The THEFT indicator will
prove out for three seconds following the ignition switch cycle and will flash following an ignition switch
OFF transition to indicate that PATS is active.
Charging System Indicator
The charging system indicator will be illuminated when the generator provides a ground signal to the
instrument cluster. The instrument cluster provides a prove- out when the ignition switch is in the RUN
position with the engine off. When the engine is started, the generator removes the ground to the
instrument cluster and extinguishes the charging system indicator.
Overdrive Off (O/D OFF) Indicator
The O/D OFF indicator is controlled by the off/on message sent from the PCM over the SCP network.
The instrument cluster does not provide a prove- out for the O/D OFF indicator, but will remain
illuminated if the overdrive has been commanded off following the instrument cluster prove- out.
Traction Control Indicator
During initialization, the instrument cluster will receive the traction control system state status message
from the traction control module to determine if the vehicle is equipped with traction control. If the
vehicle is equipped with traction control, this information will be stored in random access memory
(RAM) and the indicator will prove out for three seconds during each ignition cycle. If this message is
not received, the instrument cluster will assume that the vehicle is not traction control equipped and
the indicator will remain off. When the traction control is active, the traction control module sends the
instrument cluster a traction control active signal and the instrument cluster illuminates the traction
control indicator. When the traction control is inactive, the traction control module removes the traction
control active signal and the instrument cluster turns off the indicator.
In the event of a traction control failure, the traction control indicator will remain off and the ABS
indicator will illuminate.
Inspection and Verification 1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical and electrical damage.
Visual Inspection Chart Mechanical Electrical
z
Fuel tank z
Central junction box (CJB) fuse(s): Klj . 4 ba
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PINPOINT TEST T: THE TURN/HAZARD INDICATOR IS
NEVER/ALWAYS ON CLUSTER SERVICE ENGINE SOON
INDICATOR ACTIVE COMMAND
z
Connect the diagnostic tool.
z Key in ON position.
z Enter the following diagnostic mode
on the diagnostic tool: Instrument
Cluster Active Command.
z Trigger the instrument cluster active
command MIL.
z Did the SERVICE ENGINE SOON
indicator illuminate? Yes
REFER to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
No
GO to
S2 .
S2 CHECK FOR CORRECT
INSTRUMENT CLUSTER OPERATION z
Disconnect all instrument cluster
connectors.
z Check for:
zcorrosion
z pushed- out pins
z Connect all instrument cluster
connectors and make sure they seat
correctly.
z Operate the system and verify the
concern is still present.
z Is the concern still present? Yes
INSTALL a new instrument cluster. REFER to
Instrument Cluster
in this section. TEST the
system for normal operation.
No
The system is operating correctly at this time.
Concern may have been caused by a loose or
corroded connector. CLEAR the DTCs. REPEAT
the self- test. Test Step Result / Action to
Take T1 CHECK THE TURN SIGNAL AND HAZARD LAMPS OPERATION
CAUTION: Use the correct probe adapter(s) when making
measurements. Failure to use the correct probe adapter(s) may
damage the connector.
z Key in ON position.
z Operate the left and right turn signals.
z Operate the hazard lamps.
z Do the turn signals and hazard lamps operate correctly? Yes
GO to
T2 .
No
REFER to Section 417 - 01 .
T2 CHECK THE CIRCUIT IN QUESTION —
CIRCUIT 2 (WH/LB) (RH)
OR CIRCUIT 3 (LG/WH) (LH) z
Key in OFF position.
z Disconnect: Instrument Cluster C220a (RH) or C220b (LH).
z Key in ON position.
z Measure the voltage between the instrument cluster C220a pin 3,
circuit 3 (LG/WH), harness side and ground, while the steering
column multifunction switch is placed in the left turn position (LH); or
between the instrument cluster C220b pin 3, circuit 2 (WH/LB),
harness side and ground, while the steering column multifunction
switch is placed in the right turn position (RH). Yes
GO to
T3 .
No
REPAIR the circuit
(s) in question.
TEST the system for
normal operation. Klj . 36 ba
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z
Are the resistances correct? A4 CHECK WIRE BETWEEN HORN RELAY AND HORN
z
Key in OFF position.
z Disconnect: Horn C1262.
z Disconnect: Horn C1261.
z Measure the resistance between the horn relay connector Pin 3,
Circuit 1 (DB), harness side and horn C1261 or horn C1256
harness side; and between the horn relay connector Pin 3, Circuit
1 (DB), harness side and ground.
z Is the resistance less than 5 ohms between the horn relay and
the horns, and greater than 10,000 ohms between the horn
relay and ground? Yes
INSTALL new horns.
TEST the system for
normal operation.
No
REPAIR the circuit.
TEST the system for
normal operation.
A5 CHECK WIRE BETWEEN HORN RELAY AND AIR BAG SLIDING
CONTACT z
Key in OFF position.
z Deactivate the air bag system; refer to Section 501 - 20B .
z Disconnect: Air Bag Sliding Contact C218a.
z Measure the resistance between air bag sliding contact C218a Pin
2, Circuit 6 (YE/LG), harness side and horn relay connector Pin 1,
Circuit 6 (YE/LG) harness side.
z Is the resistance less than 5 ohms? Yes
GO to
A6 .
No
REPAIR the circuit.
TEST the system for
normal operation. A6 CHECK AIR BAG SLIDING CONTACT
z
Disconnect the steering wheel switch harness from the air bag
sliding contact.
z Measure the resistance between upper air bag sliding contact Yes
GO to
A7 . Klj . 3 ba
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PINPOINT TEST B: THE HORN SOUNDS CONTINUOUSLY connector Pin 3, Circuit 6 (component side), and air bag sliding
contact C218a Pin 2, Circuit 6 (component side).
z Is the resistance less than 5 ohms? No
INSTALL a new air
bag sliding contact.
REFER to
Section 501 - 20B . TEST the
system for normal
operation. A7 CHECK THE STEERING WHEEL SWITCH HARNESS
z
Inspect the steering wheel switch harness for chafing, opens or
possible short to ground.
z Is the steering wheel switch harness OK? Yes
INSTALL a new horn
switch. REFER to
Switch
— Horn . TEST
the system for normal
operation.
No
INSTALL a new
steering wheel switch
harness. TEST the
system for normal
operation. Test Step Result / Action to Take
B1 CHECK HORN CIRCUIT 1 (DB)
z
Key in OFF position.
z Disconnect: Horn Relay.
z Does the horn continue to sound? Yes
REPAIR Circuit 1 (DB) for short to battery. TEST
the system for normal operation.
No
GO to
B2 .
B2 CHECK HORN RELAY
z
Check the horn relay; refer to Wiring
Diagrams Cell 149.
z Is the horn relay OK? Yes
REINSTALL the horn relay. GO to
B3 .
No
INSTALL a new horn relay. TEST the system for
normal operation. B3 CHECK CIRCUIT 6 (YE/LG)
z
Disconnect: Air Bag Sliding Contact
C218a .
z Does the horn continue to sound? Yes
GO to
B4 .
No
RECONNECT the air bag sliding contact. GO to
B5 .
B4 CHECK GEM INPUT
z
Disconnect: GEM C201e. Yes Klj . 4 ba
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