boot FORD MUSTANG 2003 Owner's Manual

2.
CAUTION: Never reuse piston seals and dust boots.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
Lubricate the caliper piston, piston seal and caliper bores with clean High Performance DOT 3
Brake Fluid C6AZ-19542- AB or equivalent DOT 3 fluid meeting Ford specification ESA- M6C25-
A.
3. Install the caliper piston. Klj . 3 ba
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1. Install the piston seal.
2. Install the piston boot on the piston.
3.
CAUTION: Be careful not to damage or dislodge the piston seal.
Insert the caliper piston.
4. CAUTION: Be careful not to cock the caliper piston.
Press the caliper piston into the bore.
4. Install a new bleed screw and cap.
5. Install the disc brake caliper. For additional information, refer to Caliper in this section. Klj . 4 ba
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5. Remove the rear disc brake piston and adjuster from the caliper bore.
6. Remove and discard the piston dust boot seal and piston seal from the caliper bore.
7.
CAUTION: The parking brake lever pin retainer clip (2A746) and spring cover are
spring- loaded. Use care when removing the parking brake lever pin retainer clip.
Remove the parking brake lever pin retainer clip. zUnload the spring tension from the parking brake lever pin retainer clip and spring cover
using Screw and Cross Block, a 6- mm washer head nut and a 1/2-inch drive 14-mm
socket.
z Remove the parking brake lever pin retainer clip with suitable snap- ring pliers.
z Remove Screw and Cross Block. Klj . 2 ba
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8. Remove the following components:
1. spring cover
2. spring
3. washer
4. key plate
5. push rod
6. strut pin
7. push rod O- ring
9. Remove and discard the O- ring seal from the push rod.
10. Remove the parking brake lever (2A637). 1. Remove the parking brake return spring (2456).
2. Remove the limiting bolt (2A795).
3. Remove the parking brake lever.
4. Remove the parking brake lever shaft seal from the caliper bore.
Assembly 1. CAUTION: Do not reuse piston seals or dust boots. Install new seals or dust boots
or damage to the vehicle can occur. Klj . 3 ba
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4 N805572-
S36 Air bag module retaining screws (2 req'd)
5 3L518 Steering wheel spoke cover
(2 req'd)
6 — Lock tabs
7 14A664 Clockspring
8 13318 Turn indicator cancel cam
9 3C610 Snap ring
10 3520 Bearing spring
11 3518 Upper bearing sleeve
12 3517 Upper bearing (small)
13 3517 Lower bearing (large)
14 3524 Shaft assembly
15 390345-
S36 Screw
16 13K359 Multi-
function switch 17 3E695 Lock cam
18 3F609 Tilt wheel handle
19 N806157 Lock cam pivot pin
20 3530 Lower shroud
21 55929 Shroud retaining screws
22 3D544 Release lever
23 3B661 Lock actuator lever (RH)
24 N805856 Lock actuator lever pin
25 3D653 Lock actuator lever (LH)
26 3B664 Lock lever spring (2 req'd)
27 14A099 Wiring shield
28 3D655 Lock lever spring return
29 3E715 Lock lever upper actuator
30 3E696 Lock spring (shaft)
31 11572 Ignition switch
32 N806423-
S56 Steering column mounting lower nuts
33 N806584 Screw
34 3E660 Mounting bracket
35 3D681 Bearing retaining
36 3518 Bearing sleeve
37 3517 Lower bearing
38 3L539 Lower bearing tolerance ring
39 3C131 Sensor ring
40 3520 Bearing spring
41 N808349 Bolt —
flange yoke 42 3N725 Coupling
43 3C611 Tube boot
44 3B676 Intermediate shaft Klj . 2 ba
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DIAGNOSIS AND TESTING
Starting System
Refer to Wiring Diagrams Cell
20 , Starting System for schematic and connector information.
Inspection and Verification WARNING: When servicing starter motor or carrying out other underhood work in the
vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter
solenoid is "electrically hot" at all times. A protective cap or boot is provided over this terminal
that must be installed after servicing. Be sure to disconnect the battery negative cable before
servicing the starter. Failure to follow these instructions may result in personal injury.
WARNING: When working in area of the starter motor, be careful to avoid touching hot
exhaust components. Failure to follow these instructions may result in personal injury.
WARNING: When using a remote starter switch or jumper wire, be sure the ignition switch
is in the OFF position and the transmission is in PARK (A/T) or Neutral (M/T) with the parking
brake control fully applied.
1. Verify the customers concern by operating the starting system to duplicate the conditions.
2. Inspect to determine if any of the following mechanical or electrical concerns apply.
3. If the inspection reveals an obvious concern that can be readily identified, repair as necessary.
4. If the concern remains after the inspection, determine the symptom. GO to Symptom Chart .
SECTION 303-
06: Starting System 2003 Mustang Workshop Manual Special Tool(s)
Digital Multimeter
105-
R0051 or equivalent Visual Inspection Chart
Mechanical Electrical
z
Starter motor
z Brackets z
Battery
z Battery junction box (BJB) fuse ignition switch (40A)
z Central junction box (CJB) Fuse 6 (20A)
z Fuse 24 (10A)
z Damaged wiring harness
z Starter Relay
z Loose or corroded connections Klj . 1 ba
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Component Tests
Starter Motor —Voltage Drop Test
WARNING: When servicing starter motor or carrying out other underhood work in the
vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter
solenoid is "electrically hot" at all times. A protective cap or boot is provided over this terminal
that must be installed after servicing. Be sure to disconnect the battery negative cable before
servicing the starter. Failure to follow these instructions may result in personal injury.
WARNING: When using a remote starter switch or jumper wire, be sure the ignition switch
is in the OFF position and the transmission is in PARK (A/T) or Neutral (M/T) with the parking
brake control fully applied.
Always make the Digital Multimeter connections at the component terminal rather than at the wiring
end connector. Making a connection at the wiring end connector could result in false readings because
the meter will not pick up a high resistance between the wiring connector and the component.
Starter Motor— Motor Feed Circuit
1. Make sure the battery is fully charged. Perform a battery load test. For additional information, refer to Section 414 - 00 .
2. Disconnect the inertia fuel shut off (IFS) switch.
3. Connect a remote starter switch between the starter solenoid S- terminal and the battery positive
(+) terminal.
4. Connect the Digital Multimeter positive lead to the battery positive (+) post. Connect negative lead to the starter solenoid M- terminal. brackets for cracks.
z Check the starter motor mounting
bolts for looseness.
z Is the starter motor mounted
correctly? GO to
D2 .
No
REINSTALL the starter motor correctly. REFER to
Starter Motor — 3.8L or
Starter Motor — 4.6L in this
section. D2 INSPECT THE STARTER MOTOR
z
Remove the starter motor; refer to
Starter Motor — 3.8L or
Starter Motor — 4.6L in this section.
z Inspect the starter motor for
damage.
z Is the starter motor damaged? Yes
INSTALL a new starter motor. REFER to
Starter Motor — 3.8L or
Starter Motor — 4.6L in this section.
TEST the system for normal operation.
No
CHECK the starter drive. REFER to Component
Tests, Starter Drive Test in this section. INSTALL a
new starter motor. TEST the system for normal
operation. Klj . 8 ba
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REMOVAL AND INSTALLATION
Starter Motor —
3.8L
Removal
WARNING: When servicing starter motor (11002) or carrying out other underhood work in
the vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter
solenoid (11390) is "electrically hot" at all times. A protective cap or boot is provided over this
terminal that must be installed after servicing. Be sure to disconnect the battery negative cable
before servicing the starter. Failure to follow these instructions may result in personal injury.
WARNING: When working in area of the starter motor, be careful to avoid touching hot
exhaust components. Failure to follow these instructions may result in personal injury.
NOTE: When working on the starter system, make sure the anti- theft system is deactivated (if
equipped.)
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the ground cable nut.
4. Remove the cap.
5. Remove the nuts and position aside the wires.
SECTION 303-
06: Starting System 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Starter Motor —
4.6L
Removal
WARNING: When servicing starter motor (11002) or carrying out other underhood work in
the vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter
solenoid (11390) is "electrically hot" at all times. A protective cap or boot is provided over this
terminal that must be installed after servicing. Be sure to disconnect the battery negative cable
before servicing the starter. Failure to follow these instructions can result in personal injury.
WARNING: When working in area of the starter motor, be careful to avoid touching hot
exhaust components. Failure to follow these instructions can result in personal injury.
NOTE: When working on the starter system, make sure the anti- theft system is deactivated (if
equipped.)
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the red starter solenoid safety cap.
4. Remove the starter solenoid nuts and position aside the wires.
5. NOTE: To ease removal, remove the upper, concealed bolt first.
Remove the three starter motor bolts.
SECTION 303-
06: Starting System 2003 Mustang Workshop Manual Klj . 1 ba
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5. Remove the bolts and the ignition coil (12029).
6.
NOTE: Apply silicone brake caliper grease and dielectric compound to the inside of the spark
plug wire coil boot.
NOTE: Be sure to reinstall the radio ignition interference capacitor (18801) under the correct
mounting bolt.
To install, reverse the removal procedure. Klj . 2 ba
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