clip FORD MUSTANG 2003 Owner's Manual

Installation
1. NOTE: This procedure applies to both the LH and RH halfshafts.
Install a new driveshaft bearing retainer circlip.
2. Remove the special tool.
3. CAUTION: Differential seal damage will occur if installing the halfshaft without the
special tool installed.
Install the special tool. Klj . 5 ba
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4. Position the halfshaft for installation.
5. Seat the CV joint stub shaft in the differential side gear.
1. Slide the stub shaft into the axle housing until the shaft splines are past the differential seal.
2. Remove the special tool.
3. Align the stub shaft splines and the side gear splines, and slide the stub shaft into the gear until it seats.
„When seated, the axle circlip will lock the stub shaft in the differential side gear.
Check the circlip engagement by attempting to pull the inboard CV joint out of the
differential side gear. If the circlip has not seated, push the CV joint inward until
the circlip is fully engaged in the differential side gear.
6. Connect the axle shaft to the hub. 1. Making sure the serrations on the shaft line up with the serrations in the hub, install the axle shaft into the hub.
2. Install a new retainer. Do not tighten the retainer at this time. Klj . 6 ba
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REMOVAL AND INSTALLATION
Brake Pads —
Cobra
Removal 1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full.
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the tire and wheel assembly. For additional information, refer to Section 204 - 04 .
4. CAUTION: Install new pads if worn to or past the specified thickness above the
metal backing plate or rivets. Install new pads in complete axle sets.
Inspect the pads for wear and contamination.
5. Remove the caliper locating pin E- clip.
6. Remove the caliper locating pin.
SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Brake Caliper —
Cobra
Removal 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Remove the tire and wheel assembly. For additional information, refer to Section 204 - 04 .
3. Remove the caliper locating pin E- clip.
4. Remove the caliper locating pin.
5. Remove the front brake flow bolt. 6. Remove the caliper. SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Caliper
Removal
1. Raise the vehicle on a hoist. For additional information, refer to Section 100 - 02 .
2. Remove the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
3. Disengage the parking brake cable end from the parking brake lever arm.
4. Remove the parking brake cable retaining clip.
5. Remove the parking brake cable and conduit.
SECTION 206-
04: Rear Disc Brake 2003 Mustang Workshop Manual Special Tool(s)
Rear Caliper Piston Adjuster
206-
026 (T87P-2588- A) Klj . 1 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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SPECIFICATIONS
SECTION 206-
05: Parking Brake and Actuation 2003 Mustang Workshop Manual Torque Specifications
Description Nm Lb/Ft
Parking brake control-
to-cowl nut 17 13
Brake hose clip mounting bolt 12 9 Klj . 1 ba
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PINPOINT TEST B: PARKING BRAKE WILL NOT RELEASE to Section 100 - 02 .
z Inspect for broken or binding parking
brake cables or broken guide clips.
z Is there a parking brake cable
concern? INSTALL a new parking brake cable as
necessary. TEST the system for normal
operation.
No
GO to
A2 .
A2 CHECK THE PARKING BRAKE
CONTROL z
Operate the parking brake control.
z Does the parking brake control
operate smoothly? Yes
INSTALL a new parking brake lever. RESTORE
vehicle and TEST the system for normal
operation.
No
REPAIR the binding condition in the parking brake
control. TEST the system for normal operation.
Test Step Result / Action to Take
B1 CHECK PARKING BRAKE CONTROL
z
Raise and support the vehicle. Refer to
Section 100 - 02 .
z Release parking brake by pulling
upward on hand lever and pushing
release button.
z Did parking brake release? Yes
GO to
B2 .
No
INSTALL a new parking brake control.
RESTORE the vehicle and TEST the system for
normal operation. B2 CHECK PARKING BRAKE CABLES
z
Loosen tensioner. Refer to Parking Brake Cable Tension Release in this
section.
z Move the gearshift lever to NEUTRAL
position.
z Rotate rear wheels by hand.
z Did rear wheels turn freely? Yes
GO to
B3 .
No
INSTALL new parking brake cables. RESTORE
the vehicle and TEST the system for normal
operation. B3 CHECK REAR PARKING BRAKE
LEVERS z
Disconnect parking brake levers one at
a time.
z Rotate wheel affected by disconnected
parking brake lever.
z Did wheel turn freely? Yes
INSTALL a new parking brake lever. RESTORE
vehicle and TEST the system for normal
operation.
No
REPAIR or INSTALL a new rear brake
component if worn or damaged. TEST the
system for normal operation. Klj . 2 ba
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4. Remove the parking brake rear cable and conduit from the routing clip bolts.
5. Disconnect the parking brake rear cable and conduit from the parking brake lever (2A637).
6. Remove the clip from the rear disc brake caliper (2552). Klj . 2 ba
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REMOVAL AND INSTALLATION
Sensor —
Front
Removal 1. Remove the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
2. Remove the inner fender splash shield. 1. Remove the inner fender splash shield push pins.
2. Remove the inner fender splash shield screw.
3. Remove the inner fender splash shield.
3. Remove the front anti- lock brake sensor electrical connector.
4. Remove the front anti- lock brake sensor harness from the anti- lock brake sensor harness clips.
5. Remove the front anti- lock brake sensor.
1. Remove the front anti- lock brake sensor bolt.
2. Remove the anti- lock brake sensor harness from the harness clips.
3. Remove the front anti- lock brake sensor.
SECTION 206-
09A: Anti-Lock Control — Rear 2003 Mustang Workshop Manual Klj . 1 ba
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