check oil FORD MUSTANG 2003 Owner's Manual

crayon or chalk.
6. While holding the crayon or chalk against the tire, rotate the wheel slowly in the opposite direction until the feeling of driving the rear axle is encountered again.
7. Measure the length of the crayon or chalk mark on the tire. zIf the length of the mark is 25.4 mm (1 inch) or less, the rear axle backlash is within
allowable limits.
z If the chalk mark is greater than 25.4 mm (1 inch), check for these conditions:
„Elongation of the differential pinion shaft and holes in the differential case (4204).
„ Missing differential pinion thrust washer (4230) or differential side gear thrust
washer (4228).
„ Galling of the differential pinion shaft (4211) and bore.
„ Excessive ring gear and pinion backlash. Follow the procedure for the type of rear
axle to check backlash.
Axle Shaft Bearing Noise
Axle bearing shaft noise is similar to gear noise and differential pinion bearing whine. Axle shaft
bearing noise will usually distinguish itself from gear noise by occurring in all driving modes (drive,
coast, and float), and will persist with the transmission in NEUTRAL while the vehicle is moving at the
speed in which the concern is occurring. If the vehicle makes this noise, remove the suspect axle
shaft, install a new bearing and a new axle seal. Re- evaluate the vehicle for noise before removing any
internal components.
Bearing Rumble
Bearing rumble sounds like marbles being tumbled. This condition is usually caused by a
worn/damaged wheel bearing. The lower pitch is because the wheel bearing turns at only about one-
third of the driveshaft speed. Wheel bearing noise also may be high- pitched, similar to gear noise, but
will be evident in all four driving modes.
Symptom Chart
Symptom Chart Condition
Possible Sources Action
z Traction- Lok®
does not work in
snow, mud or on
ice z
Differential. zCARRY OUT the Traction-
Lok® Differential Operation
Check in this section. REPAIR
as necessary. REFER to
Section 205 - 02A or
Section 205 - 02B .
z Lubricant leaking
from the pinion
seal, axle shaft oil
seals z
Vent.
z Damage in the
seal contact area
or damaged or
worn seal. z
CLEAN the axle housing vent.
z INSTALL a new seal if
damage is found.
z Differential side
gears/pinion
gears are scored z
Insufficient
lubrication. z
INSTALL new gears. REFER
to Section 205 - 02A or
Section 205 - 02B . FILL the axle to
specification.
z Incorrect or
contaminated z
INSTALL new gears. REFER
to Section 205 - 02A or
Section Klj . 10 ba
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SPECIFICATIONS
a
In- vehicle repair refill capacities are determined by filling the rear axle with the specified lubricant to
6.4- 14.3- mm (1/4- 9/16-in) below the bottom of the fill hole.
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual General Specifications
Item Specification
Lubes and Sealers
SAE 80W-
90 Premium Rear Axle Lubricant XY-
80W90- QL WSP-
M2C197- A Premium Long-
Life Grease XG -1-C ESA-
M1C75- B Rust Penetrant and Inhibitor F2AZ-19A501-
A ESR-
M99C56- A High Temperature Nickel Anti-
Sieze Lubricant
F6AZ- 9L494- AA ESE-
M124A- A Clear Silicone Rubber F7AZ-
19554-CA ESB-
M4G92- A Threadlock and Sealer EOAZ-19554-
AA WSK-
M2G351- A5 Lubricant Fill Level Checks
Approximate axle fill capacity
a 1.54-1.66-
liters (3.25-3.50- pints)
6.4-14.3- mm (1/4-9/16- in) below the bottom of
the fill hole Clearance, Tolerance and Adjustments
Maximum ring gear back face runout 0.102 mm (0.004 in)
Maximum differential case runout 0.076 mm (0.003 in)
Differential side gear thrust washer thickness 0.762 mm -
0.813 mm (0.030 in - 0.032 in) Differential pinion gear thrust washer thickness 0.762 mm -
0.813 mm (0.030 in - 0.032 in) Maximum axle shaft end play 0.762 mm (0.030 in)
Ring gear backlash 0.203 mm-
0.381 mm
(0.008 in- 0.015 in)
[(0.305 mm- 0.381 mm
(0.012 in- 0.015 in) preferred] Variation between teeth maximum backlash 0.102 mm (0.004 in)
Pinion flange runout 0.25 mm (0.010 in) T.I.R.
Torque Specifications Description Nm lb-
ft lb-
in Bolt retaining the differential pinion shaft to the differential case 30 22 —
Bolt retaining the driveshaft yoke to the pinion flange 112 83 —
Bolt retaining the differential housing cover to the differential housing 44 32 —
Oil filler plug 30 22 —
Pinion bearing preload (used pinion bearings) 0.9-
1.5 — 8-
14 Pinion bearing preload (new pinion bearings) 1.8-
3.3 — 16-
29 Adapter for 205-
S127 2.2 — 20 Klj . 1 ba
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PINPOINT TEST F: HYDRO-
BOOST ERRATIC OPERATION, STICKS,
BINDS OR GRABS z
Check accessory drive belt tension and
condition. Refer to Section 303 - 05 .
z Is the accessory drive belt OK? Yes
GO to
E3 .
No
INSTALL a new accessory drive belt.
REFER to Section 303 - 05 .
E3 CHECK POWER STEERING HOSES
z
Check power steering pressure hoses, power
steering gear pressure hoses and power
steering return hose for cracks or leaks.
z Do power steering pressure hose, power
steering gear hose and power steering
return hose check OK? Yes
GO to
E4 .
No
INSTALL new hoses as necessary.
REFER to Section 211 - 00 .
E4 CHECK BRAKE PEDAL LINKAGE
z
Check brake pedal linkage for binding or
sticking operation.
z Does pedal linkage check OK? Yes
GO to
E5 .
No
INSTALL new pedal linkage as necessary.
REFER to Section 206 - 06 .
E5 CHECK POWER STEERING PUMP SPEED
z
Check engine idle speed against
specifications.
z Is engine idle speed OK? Yes
GO to
E6 .
No
SET engine idle speed to specification.
REFER to Powertrain Control/Emissions
Diagnosis (PC/ED) manual. E6 CHECK FOR PLUGGED RETURN HOSE
z
NOTE: The return hose from the oil cooler to
the power steering reservoir has an in- line
filter in the hose.
z Disconnect power steering return hose from
power steering fluid cooler and power
steering pump reservoir.
z Pass air through hose from the oil cooler end.
z Is hose plugged? Yes
INSTALL a new power steering return
hose.
No
GO to
E7 .
E7 CHECK POWER STEERING PUMP FLOW
AND RELIEF z
Test power steering pump for correct flow
and relief pressure. Refer to Section 211 - 00 .
z Is power steering pump operating
correctly? Yes
INSTALL a new power brake hydro-
boost
unit. REFER to Section 206 - 07 .
No
INSTALL a new power steering pump.
REFER to Section 211 - 02 .
Test Step Result / Action to
Take F1 CHECK SUPPLY HOSE
z
Check for obstructions in power steering return hose and Yes Klj . 11 ba
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10. Inspect the front disc brake anchor plate assembly.
zCheck the guide pin boots for damage.
z Check the guide pins for binding and damage.
z Worn or damaged pins should be installed new.
Installation 1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the
pad lining material. Do not install contaminated pads.
NOTE: Install all hardware supplied with pad kits.
Install the pads. 1. Install the new pad slippers.
2. Install the pads. Klj . 4 ba
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GENERAL PROCEDURES
Hydro-
Boost Bleeding
1. NOTE: The Hydro- Boost power brake booster (2B560) is generally self- bleeding, and the
following procedure will normally bleed the air from the power brake booster. Normal operation
of the vehicle will further remove any additional trapped air.
Fill the power steering oil reservoir (3A697) with MERCON® Multi- Purpose ATF XT-2-QDX or
MERCON® equivalent.
2. Remove the powertrain control module (PCM) fuse to prevent the engine from starting.
3. Crank the engine for several seconds.
4. Check the fluid level in the power steering oil reservoir and add if necessary. Install the powertrain control module (PCM) fuse.
5. Start the engine.
6. With the engine running, turn the steering wheel (3600) from stop- to-stop twice. Turn the engine
off.
7. Depress the brake pedal (2455) several times to discharge the accumulator.
8. Repeat Steps 5 and 6.
9. If foaming occurs, stop the engine and allow the foam to dissipate.
10. Repeat Steps 5 and 6 as required, until all the air is removed from the system (when the foaming stops).
SECTION 206-
07: Power Brake Actuation 2003 Mustang Workshop Manual Klj . 1 ba
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GENERAL PROCEDURES
System Flushing —
CII Power Steering Pump
WARNING: Do not mix oil types. Any mixture or any unapproved oil can lead to seal
deterioration and leaks. A leak can ultimately cause loss of fluid, which can result in a loss of
power steering assist.
1. Remove the fuel pump fuse from the battery junction box.
2. Disconnect the power steering return hose. Plug the reservoir.
3. Attach an extension hose between the power steering return hose and an empty container.
4. Raise the front wheels off the floor. For additional information, refer to Section 100 - 02 .
5. Check the fluid level. If necessary, fill the reservoir to the correct level. zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
6. CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow the
starter to cool for 1 minute before cranking again. Premature starter failure can occur.
CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump will occur.
Turn the steering wheel from stop- to-stop while cranking the engine until the fluid exiting the
power steering return hose is clear of all contamination and foreign material.
zAdd Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent as
needed.
7. Lower the vehicle.
8. Disconnect the extension hose from the power steering return hose. Remove the plug. Attach the power steering return hose to the reservoir.
SECTION 211-
00: Steering System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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GENERAL PROCEDURES
System Flushing —
CIII Power Steering Pump
WARNING: Do not mix oil types. Any mixture or any unapproved oil can lead to seal
deterioration and leaks. A leak can ultimately cause loss of fluid, which can result in a loss of
power steering assist.
1. Remove the fuel pump fuse from the battery junction box.
2. Disconnect the power steering return hose. Plug the reservoir.
3. Attach an extension hose between the power steering return hose and an empty container.
4. Raise the front wheels off the floor. For additional information, refer to Section 100 - 02 .
5. Check the fluid level. If necessary, fill the reservoir to the correct level. zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
6. CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow the
starter to cool for 1 minute before cranking again. Premature starter failure can occur.
CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump could occur.
Turn the steering wheel from stop- to-stop while cranking the engine until the fluid exiting the
power steering return hose is clear of all contamination and foreign material.
zAdd Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent as
needed.
7. Lower the vehicle.
8. Disconnect the extension hose from the power steering return hose. Remove the plug. Attach the power steering return hose to the reservoir.
SECTION 211-
00: Steering System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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GENERAL PROCEDURES
Fill
1. WARNING: Do not mix oil types, any mixture or any unapproved oil can lead to seal
deterioration and leaks. A leak can ultimately cause loss of fluid, which can result in a
loss of power steering assist.
Check the fluid level. If necessary, fill the reservoir to the correct level.
zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
2. Remove the fuel pump fuse from the battery junction box.
3. Raise the front wheels off the floor. For additional information, refer to Section 100 - 02 .
4. CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow the
starter to cool for 1 minute before cranking again. Premature starter failure can occur.
CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump will occur.
Turn the steering wheel from stop- to-stop while cranking the engine.
5. Lower the vehicle.
6. CAUTION: Do not overfill the reservoir.
Check the fluid level. If necessary, fill the reservoir to the correct level. zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
7. Install the fuel pump fuse.
SECTION 211-
00: Steering System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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z
check the connections to the vehicle.
z check the ignition switch position.
4. If the scan tool still does not communicate with the vehicle, refer to the scan tool manual.
5. Carry out the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: zCKT914, CKT915 or CKT70 =ALL ECUS NO RESP/NOT EQUIP, refer to Section 418 -
00 .
z NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.
z SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs),
erase the continuous DTCs and carry out self- test diagnostics for the GEM.
6. If the DTCs retrieved are related to the concern, go to the GEM Diagnostic Trouble Code (DTC) Index to continue diagnostics.
7. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics.
GEM Diagnostic Trouble Code (DTC) Index GEM Diagnostic Trouble Code (DTC) Index DTC Description Source Action
B1217 Horn Relay Coil Circuit Failure GEM REFER to
Section 413 - 06 .
B1218 Horn Relay Coil Circuit Short to
Vbatt GEM REFER to
Section 413 - 06 .
B1312 Lamp Headlamp Input Circuit
Short to Battery GEM REFER to
Section 417 - 01 .
B1317 Battery Voltage High GEM REFER to
Section 414 - 00 .
B1318 Battery Voltage Low GEM REFER to
Section 414 - 00 .
B1322 Driver Door Ajar Circuit Short to
Ground GEM REFER to
Section 417 - 02 .
B1330 Passenger Door Ajar Circuit
Short to Ground GEM REFER to
Section 417 - 02 .
B1334 Decklid Ajar Rear Door Circuit
Short to Ground GEM REFER to
Section 417 - 02 .
B1339 Chime Input Request Circuit
Short to Battery GEM REFER to
Section 413 - 09 .
B1340 Chime Input Request Circuit
Short to Ground GEM REFER to
Section 413 - 09 .
B1342 ECU Is Defective GEM CLEAR the DTC. Retrieve the DTCs. If DTC
B1342 is retrieved, INSTALL a new GEM. REFER to Section 419 - 10 .
B1353 Ignition Key-
In Circuit Open GEM REFER to
Section 413 - 09 .
B1359 Ignition Run/Acc Circuit Failure GEM GO to
Pinpoint Test E .
B1396 Power Door Lock Circuit Short
to Battery GEM REFER to
Section 501 - 14B .
B1397 Power Door Unlock Circuit
Short to Battery GEM REFER to
Section 501 - 14B . Klj . 2 ba
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z
intake manifold gaskets
z cylinder head gaskets
z oil bypass filter
z oil filter adapter
z engine front cover
z oil filter adapter and filter body
z oil level indicator tube connection
z oil pressure sensor
Leakage Points— Under Engine—With Vehicle on Hoist
z oil pan gaskets (6710)
z oil pan sealer
z oil pan rear seal (6723)
z engine front cover gasket
z crankshaft front seal (6700)
z crankshaft rear oil seal (6701)
z crankshaft main bearing cap side bolts
z oil filter adapter and filter body
z oil cooler, if equipped
Leakage Points— With Transmission and Flywheel Removed
z crankshaft rear oil seal
z rear main bearing cap parting line
z rear main bearing cap and seals
z flywheel mounting bolt holes (with flywheel [6375] installed)
z camshaft rear bearing covers (6266) or pipe plugs at the end of oil passages
Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected
when using the dye method.
Compression Test— Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery (10655) is correctly charged. Operate the vehicle until the engine is at normal operating
temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs
(12405).
2. Set the throttle plates in the wide- open position.
3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder.
4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression
strokes and record the highest reading. Note the approximate number of compression strokes Klj . 7 ba
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