brake light FORD MUSTANG 2003 Owner's Manual

NOTE:
Use new brake fluid when assembling and bleeding the brake system.
NOTE: Lightly lubricate the parking brake lever bore, limiting bolt, parking brake lever shaft and
parking brake shaft recess with Silicone Dielectric Compound D7AZ-19A331- A or equivalent
meeting Ford specification ESE- M1C171-A.
Follow the disassembly procedure in reverse order. Klj . 4 ba
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REMOVAL AND INSTALLATION
Pedal and Bracket
Removal
1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414 -
01 .
2. Remove the stoplight switch retaining pin.
3. Slide the stoplight switch (13480) and booster push rod from the brake pedal pin.
4. Remove the brake pedal bracket retaining bolt.
5. Remove the brake pedal bracket retaining nuts.
SECTION 206-
06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Brake Booster —
Vacuum
Removal 1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414 -
01 .
2. Remove the air cleaner housing. For additional information, refer to Section 303 - 12 .
3. Remove the brake master cylinder nuts.
4. Position the brake master cylinder (2140) aside.
5. With the engine off, depress the brake pedal (2455) several times to discharge the accumulator. Disconnect the booster vacuum hose.
6. Remove the stoplight switch self- locking pin.
SECTION 206-
07: Power Brake Actuation 2003 Mustang Workshop Manual Klj . 1 ba
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7. Remove the stoplight switch (13480) and the brake booster push rod from the brake pedal pin.
8. Remove the power brake booster nuts.
9. Remove the power brake booster (2005).
Installation 1. Follow the removal procedure in reverse order. Klj . 2 ba
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5. Disconnect the power steering return line hose (3A005).
6. Disconnect the power steering pressure lines.
7. Remove the self-
locking pin.
8. Remove the stoplight switch (13480) and the brake booster push rod from the brake pedal pin. Klj . 2 ba
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4. WORN RINGS OR DILUTED OIL: When the engine is accelerated (dotted needle), the needle
drops to 0 kPa (0 in- Hg). Upon deceleration, the needle runs slightly above 74 kPa (22 in- Hg).
5. STICKING VALVES: When the needle (dotted) remains steady at a normal vacuum but occasionally flicks (sharp, fast movement) down and back about 13 kPa (4 in- Hg), one or more
valves may be sticking.
6. BURNED OR WARPED VALVES: A regular, evenly- spaced, downscale flicking of the needle
indicates one or more burned or warped valves. Insufficient hydraulic lash adjuster or hydraulic
lash adjuster (HLA) clearance will also cause this reaction.
7. POOR VALVE SEATING: A small but regular downscale flicking can mean one or more valves are not seating.
8. WORN VALVE GUIDES: When the needle oscillates over about a 13 kPa (4 in- Hg) range at idle
speed, the valve guides could be worn. As engine speed increases, the needle will become
steady if guides are responsible.
9. WEAK VALVE SPRINGS: When the needle oscillation becomes more violent as engine rpm is increased, weak valve springs are indicated. The reading at idle could be relatively steady.
10. LATE VALVE TIMING: A steady but low reading could be caused by late valve timing.
11. IGNITION TIMING RETARDING: Retarded ignition timing will produce a steady but somewhat low reading.
12. INSUFFICIENT SPARK PLUG GAP: When spark plugs are gapped too close, a regular, small pulsation of the needle can occur.
13. INTAKE LEAK: A low, steady reading can be caused by an intake manifold or throttle body gasket leak.
14. BLOWN HEAD GASKET: A regular drop of fair magnitude can be caused by a blown head gasket or warped cylinder head- to-cylinder block surface.
15. RESTRICTED EXHAUST SYSTEM: When the engine is first started and is idled, the reading may be normal, but as the engine rpm is increased, the back pressure caused by a clogged
muffler (5230), kinked tail pipe or other concerns will cause the needle to slowly drop to 0 kPa
(0 in-Hg). The needle then may slowly rise. Excessive exhaust clogging will cause the needle to
drop to a low point even if the engine is only idling.
16. When vacuum leaks are indicated, search out and correct the cause. Excess air leaking into the system will upset the fuel mixture and cause concerns such as rough idle, missing on
acceleration or burned valves. If the leak exists in an accessory unit such as the power brake
booster (2005), the unit will not function correctly. Always fix vacuum leaks.
Excessive Engine Oil Consumption
The amount of oil an engine uses will vary with the way the vehicle is driven in addition to normal
engine- to-engine variation. This is especially true during the first 16,100 km (10,000 miles) when a new
engine is being broken in or until certain internal engine components become conditioned. Vehicles
used in heavy- duty operation may use more oil. The following are examples of heavy- duty operation:
z trailer towing applications
z severe loading applications
z sustained high speed operation Klj . 12 ba
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(operating at steady speed, i.e. 64 km/h (40 mph)
regardless of transmission range. Verify by
manually selecting 2nd, OD cancel, and OD. —
REFER to Section 100 - 04 and
Diagnosis By Symptom —
Noise/Vibration Routine 254/354 in
this section for further diagnosis. No ·
GO to Step 4. 4) Is the problem engine-
rpm dependent?
(Occurs at the same engine rpm independent of
transmission gear. Verify by holding same rpm in
each transmission gear.) Yes ·
Not torque converter clutch shudder
— REFER to Section 100 - 04 and
Diagnosis By Symptom —
Noise/Vibration Routine 254/354 in
this section for further diagnosis. No ·
GO to Step 5. 5) Does the problem occur in coast, steady
speed, or reverse range? Yes ·
Not torque converter clutch shudder
— REFER to Section 100 - 04 and
Diagnosis By Symptom —
Noise/Vibration Routine 254/354 in
this section for further diagnosis. No ·
GO to Step 6. 6) Does vibration occur during extended light
brake application? Yes ·
Not torque converter clutch shudder
— REFER to Section 100 - 04 ,
Section 206 - 00 and
Diagnosis By Symptom —
Noise/Vibration Routine
254/354 in this section for further
diagnosis. No ·
GO to Step 7. 7) If one of the driving modes in Step 2 identifies
a vibration which was not present in Steps 3-
6,
then there is a strong possibility that the vibration
is caused by the torque converter clutch function.
Carry out the repair procedures as found under
Disassembly/Assembly. Klj . 3 ba
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DIAGNOSIS AND TESTING
Transmission Drive Cycle Test
NOTE:
Always drive the vehicle in a safe manner according to driving conditions and obey all traffic
laws.
NOTE: The Transmission Drive Cycle Test must be followed exactly. Malfunctions must occur four
times consecutively for shift error DTC code to be set, and five times consecutively for continuous TCC
code to set.
NOTE: When carrying out the Transmission Drive Cycle Test, refer to the Solenoid Application Chart
for correct solenoid operation.
After carrying out the Quick Test, use the Transmission Drive Cycle Test for checking continuous
codes.
1. Record and then erase Quick Test codes.
2. Warm engine to normal operating temperature.
3. Make sure transmission fluid level is correct.
4. With transmission in OVERDRIVE, moderately accelerate from stop to 80 km/h (50 mph). This allows the transmission to shift into fourth gear. Hold speed and throttle open steady for a
minimum of 15 seconds.
5. With transmission in fourth gear and maintaining steady speed and throttle opening, lightly apply and release brake to operate stoplamps. Then hold speed and throttle steady for a
minimum of five seconds.
6. Brake to a stop and remain stopped for a minimum of 20 seconds.
7. Repeat steps 4 through 6 at least five times.
8. Carry out Quick Test and record continuous DTCs. zIf the DTCs are still present, refer to the Diagnostic Trouble Code Chart. Repair all non
transmission DTCs first as they can directly affect the operation of the transmission.
Repeat the Quick Test and the Road Test to verify the correction. Erase the DTCs, carry
out the Drive Cycle Test and repeat the Quick Test after completing repair on the DTC.
z If the continuous test passes and a concern is still present, refer to Diagnosis By Symptom in this section, OASIS messages, and TSBs for concerns.
After On- Board Diagnostic
NOTE: The vehicle wiring harness, PCM and non- transmission sensors may affect transmission
operations. Repair these concerns first.
After the on- board diagnostic procedures are completed, repair all DTCs.
Begin with non- transmission related DTCs, then repair any transmission related DTCs. Use the
diagnostic trouble code chart for information on condition and symptoms. This chart will be helpful in
referring to the correct manual(s) and aids in diagnosing internal transmission concerns and external
non- transmission inputs. The pinpoint tests are used in diagnosing transmission electrical concerns.
Make sure that the vehicle wiring harness and the PCM are diagnosed as well. The Powertrain SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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manual.
P1460 A/C A/C clutch
cycling
pressure
switch error A/C or defrost on
condition may
result from A/C
clutch being on
during on-
board
diagnostic. DTC set during on-
board diagnostic,
repeat with A/C off.
Failed on, EPC
pressure slightly
low with A/C OFF. REFER to the
Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
P1636 PCM PCM detected
internal error — — REFER to the
Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
P1703 BPP BPP switch
circuit failed. Brake ON/OFF
circuit failure. Failed ON or not
connected —
torque converter
clutch will not
engage at less than
1/3 throttle. Failed
OFF or not
connected —
torque converter
clutch will not
disengage when
brake is applied. REFER to the
Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
P1703 BPP Brake not
actuated
during on-
board
diagnostic Brake not cycled
during KOER. Failed OFF or not
connected —
torque converter
clutch will not
engage at less than
1/3 throttle. Failed
OFF or not
connected —
torque converter
clutch will not
disengage when
brake is applied. REFER to the
Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
P0740 TCC, wiring,
PCM TCC electrical
circuit failure TCC circuit fails to
provide voltage
drop across
solenoid. Circuit
open or shorted or
PCM driver failed
during on-
board
diagnostic. Short circuit: engine
stalls in second
(OD, 2 range) at
low idle speeds with
brake applied.
Open circuit: torque
converter clutch
never engages.
Flashing
Transmission
Control Indicator
Lamp (TCIL). Go To Pinpoint
Test A .
P1740 TCC TCC
malfunction Mechanical failure
of the solenoid
detected. Failed ON —
Engine stalls in 2nd
(O/D, Manual 2
ranges) at low idle
speeds with brake
applied. Failed OFF
—
Torque
Converter never
applies. Go To Pinpoint
Test F .
P1741
b TCC,
internal Excessive
torque Excessive
variations in slip Engine rpm
oscillation is Go To Pinpoint
Test A . Klj . 6 ba
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Pinpoint Tests
PINPOINT TEST A: THE SHIFT INTERLOCK SYSTEM DOES NOT
RELEASE/LOCK CORRECTLY z
The shift control is
out of correct gear
relationship z
Transmission shift
cable and bracket.
z Retainer bracket.
z Shift control linkage
out of adjustment. z
Go To Pinpoint Test B .
z Transmission range
indicator does not
correspond to the
gear z
Transmission shift
cable bracket. z
TIGHTEN the bolts
holding transmission
shift cable bracket.
z Transmission shift
cable loose from the
transmission
retainer bracket. z
TIGHTEN the bolts.
z Shift linkage. zVERIFY digital
transmission range
(DTR) sensor range for
correct adjustment.
REFER to Section 307 -
01 .
z The Transmission
Control Switch (TCS)
Is Inoperative z
CJB Fuse 28 (15A).
z TCS.
z TCS not cycled
during self- test.
z Powertrain control
module (PCM).
z Circuitry. z
Go To Pinpoint Test C .
z The Transmission
Control Indicator
Lamp (TCIL) Is Not
Operating Correctly z
Bulb.
z Instrument cluster.
z Powertrain control
module. z
REFER to Section 413 -
01 .
z Excessive Shift Effort zTransmission shift
cable. z
INSTALL a new
transmission shift cable.
z Cable bracket. zADJUST the cable.
TIGHTEN the screws.
z Transmission Range
Selector Lever Will
Not Shift z
Transmission shift
cable. z
INSTALL a new
transmission shift cable.
z Broken transmission
shift cable. z
INSTALL a new
transmission shift cable. Test Step Result / Action to Take
A1 TEST THE BRAKE LIGHTS
z
Key in ON position.
z Apply the brake pedal and observe the stoplamps.
z Do the stoplamps illuminate? Yes
GO to
A2 .
No
REFER to Section 417 -Klj . 2 ba
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