Test G FORD MUSTANG 2003 Workshop Manual

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Cleaning And Inspection
1. If a new torque converter is being installed, continue with Substep 2 of Step 2.
2. If a new torque converter is not being installed, the following procedures must be performed: 1. The torque converter must be thoroughly cleaned.
„Torque converters with drain plugs can be cleaned by using a suitable torque
converter/fluid cooler cleaner.
„ Torque converters without drain plugs can be cleaned by hand. Partially fill the
torque converter using only recommended transmission fluid for the applicable
transmission. Hand agitate the torque converter and then thoroughly drain the
fluid. Refill the torque converter with clean automatic transmission fluid specified
for transmission, and reinstall.
2. All in- tank and auxiliary coolers must be thoroughly cleaned by forward and backward
flushing. For additional information, refer to Transmission Fluid Cooler — Backflushing
and Cleaning in this section.
3. All cooler lines must be thoroughly cleaned by backward and forward flushing. For additional information, refer to Transmission Fluid Cooler — Backflushing and Cleaning
in this section.
4. All Cooler Bypass Valves (CBV), if equipped, must be thoroughly cleaned.
5. Carry out the Transmission Fluid Cooler Flow Test. For additional information, refer to
Transmission Fluid Cooler — Backflushing and Cleaning in this section.
6. If the transmission cooling system fails the Transmission Fluid Cooler Flow Test, a new fluid cooler, cooler bypass valve, and/or cooler lines must be installed. For additional
information, refer to Section 307 - 02 .
7. If new coolers are to be installed, use only factory approved service parts.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Material
Item Specification
MERCON® V Automatic
Transmission Fluid
XT
-5-QM, XT -5-DM MERCON® V Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Leak Check
1. Clean the outside surface of the torque converter.
2. Install the special tool into the converter hub.
3. WARNING: Always follow correct safety procedures while using press. Failure to
follow these instructions may result in personal injury.
Install the torque converter with the installed special tool into the arbor press.
Secure the press, apply enough force to seal the tool into the torque converter.
4. NOTE: Use clean dry shop air.
Apply air pressure to the valve on the special tool.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Leak Tester, Torque Converter
307-
421 Klj . 1 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Impeller to Pump Stator Interference
Check
1. NOTE: Front pump support may remain in front pump support and gear during this test.
Position the front pump support with the splines up.
2. Mount the torque converter on the front pump support with the splines on the one- way clutch
inner race, engaging the mating splines of the front pump support.
3. Hold the front pump support stationary and rotate the torque converter counterclockwise. zThe torque converter should rotate freely with no signs of scraping.
z If there are signs of scraping, install a new or remanufactured torque converter.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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z
If the torque converter fails the lockup test torque, install a new or remanufactured torque
converter. Klj . 2 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter Turbine to Pump Stator Interference
Check
1. NOTE: Front pump support may remain in front pump support and gear during this test.
Position the torque converter with the pump drive up.
2. Install the front pump support to engage the mating splines of the front pump support shaft on the torque converter.
3. Install the forward clutch cylinder and shaft, engaging the splines with the rear clutch hub.
4. Check for stator to turbine interference. 1. Hold the front pump support stationary.
2. Attempt to rotate the forward clutch cylinder and shaft.
„The turbine and torque converter clutch assemblies should rotate in both
directions, not exceeding maximum torque of 9.5 Nm (7 lb- ft), without any signs of
metallic interference or scraping noise.
5. If interference exists, the stator front thrust washer may be worn, allowing the stator to hit the turbine. In such cases, a new or remanufactured torque converter must be installed.
zThe converter crankshaft pilot should be checked for nicks or damaged surfaces that
could cause interference when installing the torque converter into the crankshaft. Check
the converter front impeller hub for nicks or sharp edges that would damage the pump
seal.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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307-
077 (T80L-77110- A) Handle, Torque Converter
307-
091 (T81P-7902- C) Test Plate Screw Set,
Transmission
307-
126 (T82P-7006- C) Air Test Plate, Transmission
307-
246 (T92P-7006- A) Remover/Installer, Servo
Piston
307-
251 (T92P-70023- A) Retainer, Torque Converter
307-
346 (T97T-7902- A) Installer, Transmission
Extension Housing Oil Seal
308-
002 (T61L-7657- A) Gauge, Transmission Solenoid
Connectors
307-426
Material Item Specification
Multi-
Purpose Grease ESB-
M1C93- Klj . 2 ba
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52. Install the 2-
3 accumulator assembly.
1. Install the accumulator piston.
2. Install the accumulator piston spring.
3. Install the accumulator spring retainer.
53. Using the special tools apply regulated air pressure to the test ports. Verify that the components are applied and released.
54. NOTE: The tab on the electrical connector is secured by main control valve body.
Install the electrical connector into the case.
55. NOTE: The alignment bolts are valve body assembly bolts and are in the valve body.
Align the main control valve body alignment bolts and position the main control valve body. Klj . 18 ba
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DESCRIPTION AND OPERATION
Transmission Cooling —
Integral
This vehicle with an automatic transmission is equipped with an integral transmission fluid cooler. The
cooler is contained inside of the radiator outlet tank and cannot be serviced separately. The cooler
transfers heat from the transmission fluid to the engine coolant.
For transmission fluid cooler flow test, refer to Section 307 - 01 .
For transmmission fluid cooler backflushing and cleaning, refer to Section 307 - 01 .
Transmission Fluid Cooler Tubes SECTION 307-
02: Transaxle/Transmission Cooling 2003 Mustang Workshop Manual Item Part Number Description
1 — Fluid cooler inlet tube
2 — Fluid cooler outlet tube
3 7005 Transmission case
4 — Transmission case fittings Klj . 1 ba
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DIAGNOSIS AND TESTING
Transmission Cooling
Inspection and Verification
WARNING: Never remove the radiator cap under any conditions while the engine is
operating. Failure to follow these instructions could result in personal injury and/or damage to
the cooling system or engine. To avoid having scalding hot coolant or steam blow out of the
radiator, use extreme care when removing the radiator cap from a hot radiator. Wait until the
engine has cooled, then wrap a thick cloth around the radiator cap and turn it slowly to the first
stop. Step back while the pressure is released from the cooling system. When you are certain
all the pressure has been released, press down on the radiator cap (with a cloth), turn and
remove.
The transmission fluid cooler is integral to the radiator (8005). Whenever leaks or damage to the
radiator are found, install an entire new radiator. For additional information, refer to Section 303 - 03A or
Section 303 - 03B .
Symptom Chart SECTION 307-
02: Transaxle/Transmission Cooling 2003 Mustang Workshop Manual SYMPTOM CHART
Condition
Possible Sources Action
z Transmission
Overheating z
Damaged radiator. zREPAIR or install a new
radiator. For additional
information, REFER to
Section 303 - 03A or
Section 303 - 03B .
z System leaks. zINSPECT for leaks. REPAIR
as necessary.
z Incorrect fluid level. zADJUST to proper level.
z Fluid condition. zINSPECT according to
instructions under Fluid
Condition Check. REFER to
Section 307 - 01 .
z Damaged, blocked,
reversed, leaking or
restricted cooler lines
or cooler tubes. z
INSPECT cooler lines and
tubes. REPAIR or flush as
necessary.
z Engine concerns
causing transmission
to overheat. z
INSPECT engine cooling
system. For additional
information, REFER to
Section 303 - 03A or
Section 303 - 03B .
z Excessive towing
loads. z
CHECK gross vehicle weight.
z Incorrect idle or
performance. z
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual. Klj . 1 ba
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DIAGNOSIS AND TESTING
External Controls
Refer to Wiring Diagrams Cell
37 , Shift Lock for schematic and connector information.
Refer to Wiring Diagrams Cell 29 , Transmission Control for schematic and connector information.
Inspection and Verification 1. Verify the customer concern by operating the transmission external control.
2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart:
3. If the concern is not visually evident, determine the symptom. GO to Symptom Chart .
Symptom Chart SECTION 307-
05: Automatic Transaxle/Transmission External Controls 2003 Mustang Workshop Manual Special Tool(s)
73 Digital Multimeter
105-
R0051 or equivalent
Visual Inspection Chart Mechanical Electrical
z
Shift control linkage binding.
z Shift lock actuator.
z Shift control cable.
z Interlock cable. z
Circuitry.
z Central junction box (CJB) fuse:
„17 (15A)
„ 28 (15A)
„ 35 (15A)
z Brake pedal position (BPP) switch.
z Wiring harness.
z Loose or corroded connections.
z Bulb.
SYMPTOM CHART Condition
Possible Sources Action
z The shift interlock
system does not
release/lock correctly z
Circuitry.
z CJB Fuse 17 (15A)
or Fuse 35 (15A).
z Shift lock actuator.
z Brake pedal position
(BPP) switch. z
Go To Pinpoint Test A . Klj . 1 ba
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