lock FORD MUSTANG 2003 Workshop Manual

Incorrect Pressures
·
Line pressure, EPC pressure ·
Check pressure at line and EPC taps; refer to Line Pressure
Chart for specifications. If not OK, check the main controls. If
OK, refer to the shift routine(s) for further diagnosis:
„ Shift 1- 2, Routine 320
„ Shift 2- 3, Routine 321
„ Shift 3- 4, Routine 322
„ Shift 4- 3, Routine 323
„ Shift 3- 2, Routine 324
„ Shift 2- 1, Routine 325 Main Controls
·
EPC solenoid, stuck or
damaged hydraulically or
mechanically ·
Inspect for damage, contamination. Carry out EPC tests in
Routine No. 211. Repair as required. ·
Valves, accumulators, seals
stuck or damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
Solenoid screen blocked or
damaged ·
Clean or install a new screen.
Shift Concerns: Timing Concerns — Erratic/Hunting Possible Component Reference/Action
212 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, shift
solenoids, torque converter clutch
(TCC) solenoid, digital TR sensor,
output shaft speed (OSS) ·
Carry out Self- Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for
diagnosis. Go To Pinpoint Test A ,
Go To Pinpoint Test C or
Go To Pinpoint Test E . Repair as required. Clear
DTCs, road test and repeat Self- Test. ·
Poor engine performance ·
Refer to Routine 253. 312 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Main Controls
·
Valves, accumulators, seals,
assembled wrong, stuck or
damaged ·
Inspect for damage. Repair as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
Solenoid screen blocked or
damaged ·
Clean or install a new screen. Torque Converter Clutch
·
Torque converter ·
Refer to Torque Converter Operation Concerns:
Cycling/Shudder/Chatter Hydraulic/Mechanical Routine
342. Specific Shifts
·
Refer to the following shift routine(s) for further diagnosis: Klj . 12 ba
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piston
·
Springs damaged or
broken ·
Inspect for damage. Repair as required. ·
Case bore scored ·
Inspect for damage. Repair as required.
Shift Concerns: 2-3 Shift (Automatic) Possible Component Reference/Action
221 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, shift solenoids, OSS ·
Carry out Self-Test. Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Go To Pinpoint Test A or
Go To Pinpoint Test E . Repair as required. Clear DTCs, road test
and repeat Self- Test. ·
Engine driveability concerns ·
Refer to Routine 253. 321 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment. Refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable,
verify that the digital TR sensor is correctly adjusted. Adjust the
digital TR sensor as necessary. Incorrect Pressures
·
Direct clutch pressure ·
Check pressure at direct clutch tap; refer to Line Pressure
Chart for specifications. If not OK, check the main controls. Main Controls
·
2- 3 shift valve, check ball No.
9 or No. 3, solenoid pressure
regulator valve, damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Shift solenoid SSB
malfunction ·
Activate solenoid using scan tool. If solenoid operation cannot
be felt when placing hand on solenoid, install a new solenoid.
Inspect O- rings for damage. Repair as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
Output shaft seals damaged
or cup plug leaking or missing ·
Inspect for damage and repair as required. ·
2- 3 accumulator damaged or
stuck ·
Inspect piston seal and bore for damage. Repair as required. ·
Solenoid screen (in main
control) blocked or damaged ·
Clean or install a new screen. Intermediate One-
Way Clutch
Assembly ·
Not overrunning or damaged ·
Inspect for damage. Repair as required. Output Shaft
·
Seal rings damaged ·
Inspect for damage. Repair as required. ·
Cup plug damaged or missing Klj . 18 ba
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required.
·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
OD servo rod and piston cushion
spring or seals damaged ·
Inspect for damage. Repair as required. ·
Worn or damaged OD servo anchor
pins ·
Inspect for damage. Repair as required. ·
No. 2, No. 4, No. 7 and No. 9 check
balls damaged or missing ·
Inspect for damage. Repair as required. ·
Solenoid screen blocked or
damaged ·
Clean or install a new screen. Pump
·
Porosity/cross leaks, balls missing,
damaged or leaking ·
Inspect for porosity/leaks, balls missing. Install a new
pump as required. ·
Gaskets damaged ·
Inspect for damage. Install new gaskets as required. OD Band
·
OD band and reverse clutch drum
assembly damaged, worn or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
Intermediate one- way clutch
assembly damaged ·
Inspect for damage. Repair as required. Forward Clutch Assembly
·
Seals or piston damaged ·
Inspect for damage. Repair as required. ·
Friction elements worn or damaged ·
Inspect for damage. Repair as required. ·
Check ball stuck, damaged or not
seating correctly ·
Inspect for damage. Repair as required. Input Shaft
·
Seals damaged ·
Inspect for damage. Repair as required.
Shift Concerns: 4-3 Shift (Automatic) Possible Component Reference/Action
223 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle wiring
harnesses, PCM, shift solenoids,
transmission control switch (TCS) ·
Carry out Self- Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for
diagnosis and testing of the Powertrain Control
System. Go To Pinpoint Test A . Repair as required.
Clear DTCs, road test and repeat Self- Test. 323 —
HYDRAULIC/MECHANICAL ROUTINE Incorrect Pressures
·
Forward clutch pressure, line pressure ·
Check line and forward clutch at pressure taps; refer to
Line Pressure Chart for specifications. If out of
specification, check the main controls. Main Controls
·
3- 4 shift valve, solenoid pressure
regulator valve, OD servo regulator, 3-
4 capacity modulator, 1- 2 and 2-3 shift
valves stuck, damaged or assembled ·
Inspect for damage. Repair as required. Klj . 20 ba
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incorrectly
·
Check balls No. 2, No. 7, No. 9
damaged, missing or not seating
correctly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to specifications ·
Tighten bolts to specification. ·
SSA malfunction ·
Activate solenoid using scan tool. If solenoid operation
cannot be felt when placing hand on solenoid, install a
new solenoid. Inspect O- rings for damage. Repair as
required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
OD servo, seal, rod damaged ·
Inspect for damage. Repair as required. ·
Solenoid screen blocked or damaged ·
Clean or install a new screen. Pump
·
Porosity/cross leaks, balls missing,
damaged or leaking ·
Inspect for porosity/leaks, balls missing. Install a new
pump as required. ·
Seal rings damaged ·
Inspect for damage. Repair as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Overdrive Band
·
OD band and reverse clutch assembly
damaged, worn or assembled
incorrectly ·
Inspect for damage. Repair as required. ·
Intermediate one- way clutch assembly
damaged ·
Inspect for damage. Repair as required. Forward Clutch Assembly
·
Seals or piston damaged ·
Inspect for damage. Repair as required. ·
Friction elements damaged, worn ·
Inspect for damage. Repair as required. ·
Check ball stuck, damaged or not
seating correctly ·
Inspect for damage. Repair as required. ·
Forward clutch piston and return
spring damaged ·
Inspect for damage. Repair as required. Input Shaft
·
Seals damaged ·
Inspect for damage. Repair as required.
Shift Concerns: 3-2 Shift (Automatic) Possible Component Reference/Action
224 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, shift solenoids ·
Carry out Self- Test. Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Go To Pinpoint Test A . Repair as
required. Clear DTCs, road test and repeat Self- Test. 324 —
HYDRAULIC/MECHANICAL ROUTINE Incorrect Pressures
·
Direct clutch ·
Check pressure at direct clutch tap; refer to Line Pressure Chart for
specifications. If not within specification, check the main controls. Main Controls Klj . 21 ba
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Pump
·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
Porosity/cross leaks ·
Inspect for leak/porosity. Install a new pump as required. Intermediate Clutch Assembly
·
Piston damaged ·
Inspect for damage. Repair as required. ·
Friction elements damaged,
worn ·
Inspect for damage. Repair as required. ·
End clearance incorrect ·
Inspect and correct; refer to Transmission Assembly. Intermediate One-
Way Clutch ·
Damaged ·
Inspect for damage. Repair as required. ·
Intermediate one- way clutch
retaining snap ring not seated ·
Inspect for damage. Repair as required. Planetary One-
Way Clutch ·
Not holding or damaged ·
Inspect for damage. Repair as required.
Torque Converter Clutch Operation Concerns: No Apply Possible Component Reference/Action
240 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, torque
converter clutch (TCC) solenoid, TFT
sensor, OSS ·
Carry out Self- Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for
diagnosis and testing of the Powertrain Control System.
Go To Pinpoint Test B or
Go To Pinpoint Test E .
Repair as required. Clear codes, road test and repeat
Self- Test. 340 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage
·
Damaged or incorrectly adjusted ·
Inspect and repair as required. Verify transmission shift
cable adjustment; refer to Section 307 - 05 . Adjust
transmission shift cable as necessary. After repairing
transmission shift cable, verify that the digital TR
sensor is correctly adjusted. Adjust the digital TR
sensor as necessary. Incorrect Pressures
·
Low line pressure, low EPC pressure ·
Check pressure at line and EPC taps; refer to Line
Pressure Chart for specifications. If pressure is low,
check EPC and main regulator valve. If within
specifications, check the main controls. Main Controls
·
Solenoid pressure regulator valve,
manual valve, bypass clutch control
valve and plunger, converter
pressure limit valve, drain back valve
stuck, damaged or assembled
incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to specifications ·
Tighten bolts to specifications. ·
Solenoid screen blocked or damaged ·
Clean or install a new screen. ·
TCC solenoid malfunction ·
Activate solenoid using scan tool. If solenoid operation Klj . 23 ba
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·
No end clearance ·
Inspect converter and install a new or remanufactured torque
converter as required. ·
Piston plate damaged or stuck
to cover ·
If cover is heat- stained, install a new converter and determine
the cause of the overheat condition.
Torque Converter Clutch Operation Concerns: Cycling/Shudder/Chatter Possible Component Reference/Action
242 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, torque
converter clutch (TCC) solenoid,
OSS ·
Carry out Self-Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for
diagnosis and testing of the Powertrain Control System.
Go To Pinpoint Test E . Repair as required. Clear
DTCs, road test and repeat Self- Test. ·
Speed control equipped vehicles ·
Evaluate with speed control off. 342 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Condition ·
Inspect fluid condition. If burnt, drain fluid and converter.
Install a new fluid and filter assembly. Bring vehicle to
normal operating temperature. Carry out Transmission
Drive Cycle Test. Carry out Transmission Self- Test. If
condition still exists, continue diagnostics. Main Controls
·
Solenoid pressure regulator valve,
No. 7 check ball, bypass clutch
control valve and plunger, converter
pressure limit valve stuck, damaged
or assembled incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to specifications ·
Tighten bolts to specifications. ·
Solenoid screen blocked or damaged ·
Clean or install a new screen. ·
TCC solenoid malfunction ·
Activate solenoid using scan tool. If solenoid operation
cannot be felt when placing hand on solenoid, install a
new solenoid. Inspect O- rings for damage. Repair as
required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Pump Assembly
·
Bolts not tightened to specification ·
Tighten bolts to specification. ·
Porosity/cross leaks, missing balls or
leaking ·
Inspect for porosity/leaks or missing balls. Install a new
pump as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Input Shaft
·
Seals damaged ·
Inspect for damage. Repair as required. Torque Converter
·
Excessive end clearance ·
Inspect converter. Install a new or re- manufactured
torque converter as required.
Other Concerns: No Engine Braking In Manual 2nd Or Manual 1st Position Klj . 25 ba
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Possible Component Reference/Action
250 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 350 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable,
verify that the digital TR sensor is correctly adjusted. Adjust
the digital TR sensor as necessary. Main Controls
·
3- 4 shift valve, 1- 2 and 2-3
shift valve, gaskets, 3-4
capacity modulator valve,
stuck or damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
OD servo assembly damaged
or stuck in manual 2nd only. ·
Inspect cover, piston and seal for damage. Repair as required. ·
Low/Reverse servo assembly
damaged or stuck in manual
1st only ·
Inspect cover, piston and seal for damage. Repair as required. Overdrive
·
Reverse band, manual 1st
(only) damaged ·
Inspect for damage. Repair as required. ·
OD band, reverse clutch drum
assembly worn or damaged
(manual 2nd only) ·
Inspect for damage. Repair as required. Reverse Band (Manual 1st Only)
·
Damaged or incorrectly
adjusted ·
Inspect for damage. Repair as required.
Other Concerns: Shift Lever Efforts High Possible Component Reference/Action
251 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 351 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR
Sensor
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable, verify
that the digital TR sensor is correctly adjusted. Adjust the digital
TR sensor as necessary. ·
Brake shift interlock
system, solenoid damaged ·
Refer to the appropriate brake section in the workshop manual. Manual Lever
·
Retaining pin damaged, nut
loose, detent spring bent or
damaged or Park ·
Inspect for damage. Repair as required. Klj . 26 ba
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12 o'clock position
„ Friction elements ·
3rd Gear:
„ Torque converter
„ Case to planet support spring
„ Friction elements ·
4th Gear:
„ Gear set
„ Friction elements
„ Torque converter ·
Reverse:
„ Gear set
„ Friction elements ·
Output shaft splines worn or damaged Other Noises/Vibrations
·
Main controls, valve resonance ·
Shift cable:
„ Vibration
„ Grounding
„ Cooler lines
„ Grounding ·
Locate source of disturbance and repair as
required.
Other Concerns: Engine Will Not Crank Possible Component Reference/Action
255 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
engine starting system
hardware, digital TR sensor ·
Carry out Self- Test. Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Go To Pinpoint Test C . Repair and
adjust as required. 355 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR
Sensor
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable,
verify that the digital TR sensor is correctly adjusted. Adjust the
digital TR sensor as necessary.
Other Concerns: No Park (P) Range Possible Component Reference/Action
256 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 356 —
HYDRAULIC/MECHANICAL ROUTINE Klj . 29 ba
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Shift Linkage, Digital TR Sensor
·
Damaged or incorrectly adjusted ·
Inspect and repair as required. Verify transmission shift
cable adjustment; refer to Section 307 - 05 . Adjust
transmission shift cable as necessary. After repairing
transmission shift cable, verify that the digital TR sensor
is correctly adjusted. Adjust the digital TR sensor as
necessary. Park Mechanism
·
Output shaft ring, parking brake pawl,
parking pawl return spring, park rod
guide cup, parking pawl shaft,
parking pawl actuating rod, manual
lever detent spring damaged or
assembled incorrectly ·
Inspect for damage or incorrect assembly and repair as
required.
Other Concerns: Overheating Possible Component Reference/Action
257 —
ELECTRICAL ROUTINE Refer to Routine 240/340, Torque Converter Operation Concern: No Apply
357 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Other
·
Damaged, blocked or reversed cooler lines or
restriction in the transmission oil cooler ·
Inspect for damage and correct
installation. Repair as required. Vehicle Concerns Causing Engine Overheating
·
Refer to the appropriate engine
cooling section. Main Controls
·
Drain back valve, torque clutch control valve, converter
limit valve stuck, damaged or assembled incorrectly ·
Inspect for damage and repair as
required. Torque Converter Clutch
·
No apply ·
Refer to Routine 240/340. Klj . 30 ba
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IN-
VEHICLE REPAIR
Fluid Pan, Gasket and Filter
1. Normal maintenance requires periodic automatic transmission fluid changes. If a major repair, such as a clutch, band, bearing, etc., is required, the automatic transmission will also have to be
removed for repair. At this time, the torque converter, transmission cooler and tubes must be
thoroughly flushed to remove any dirt. The transmission fluid needs to be changed if evidence
of fluid contamination is found. When used under continuous or severe conditions, the
transmission and torque converter should be drained and refilled with fluid as specified.
2. CAUTION: Do not use any supplemental transmission fluid additives or cleaning
agents. The use of these products could cause internal transmission components to fail;
this will effect the operation of the transmission.
CAUTION: Use of a fluid other than specified could result in transmission failure.
Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar
for the transmission code.
3. When filling a dry transmission and torque converter, refer to General Specifications chart in this section for capacity. Check the fluid level.
Removal
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. Place a drain pan under the transmission fluid pan.
4. Drain transmission fluid. zLoosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained
remove the bolts.
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
52003 Mustang Workshop Manual
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