sensor FORD MUSTANG 2003 Workshop Manual

1. Remove the bolt and the output shaft speed (OSS) sensor.
2. Remove the bolt and the reverse lockout solenoid.
3. Remove the bolts and the reverse idler shaft bracket.
4. Remove the reverse idler gear thrust washer. 16 7A039 Extension housing Klj . 3 ba
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42. Install the lower spacer, the rear mainshaft roller bearing and the upper spacer.
43. Install the rear mainshaft roller bearing snap ring.
44. Install a new output speed shaft (OSS) sensor tone wheel lower retaining ring.
45. Using the special tool, install the OSS sensor tone wheel. Klj . 15 ba
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46. Install a new OSS sensor tone wheel retaining ring.
47. Install the shipping seal.
48. Apply threadlock and sealer to the threads of the plug, then install the plug into the transmission
adapter plate.
49. Clean the mating surfaces of the transmission main case and the extension housing. Apply a bead of silicone rubber to the sealing surface on the transmission case. Install the extension
housing and tighten the bolts. Klj . 16 ba
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INSTALLATION
Transmission
1. NOTE: Before installing the transmission, the ball stud, clutch release lever and the input shaft
must be cleaned and lubricated with grease.
Position the transmission to the clutch adapter housing. Install the eight transmission- to-clutch
adapter housing bolts.
2. Connect the output shaft speed (OSS) sensor electrical connector.
3. Connect the reverse lamp electrical connector.
SECTION 308-
03C: Manual Transaxle/Transmission — T56 2003 Mustang Workshop Manual Material
Item Specification
DEXRON III® (
ATF)
Transmission Fluid
XT -2-QDX or equivalent DEXRON III®
Pipe Sealant with Teflon®
D8AZ-
19554- A or equivalent WSK-
M2G350-
A2 Premium Long Life Grease
XG
-1-C, K or T or equivalent ESA-
M1C75- B Klj . 1 ba
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8. Remove the transmission jack from the transmission.
9. Connect the heated oxygen sensor (HO2S) electrical connectors to the crossmember.
10. CAUTION: Align the index marks on the driveshaft flange and pinion flange, and the
driveshaft slip yoke and transmission output shaft.
Install the driveshaft. For additional information, refer to Section 205 - 01 .
11. Fill the transmission to capacity with the specified transmission fluid. Apply sealant to the fill plug threads and install the fill plug.
zThe total fill capacity is 3.9L (4.1 qt).
12. Lower the vehicle.
13. Connect the reverse lockout solenoid electrical connector. Klj . 3 ba
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DESCRIPTION AND OPERATION
Exhaust System
WARNING: The normal operating temperature of the exhaust system is very high. Never
attempt to repair any part of the system until it has cooled. Be especially careful when working
around the three way catalytic converter. The temperature of the three way catalytic converter
rises to a high level after only a few minutes of engine operation.
CAUTION: When repairing exhaust system or removing exhaust components, disconnect
all heated oxygen sensors (HO2S) at the wiring connectors to prevent damage to the heated
oxygen sensors and wiring harness. For additional information, refer to Section 303 - 14 for
location of the heated oxygen sensors.
The exhaust system:
zcontains dual three- way catalytic converters.
z has a crossover pipe downstream of the three way catalytic converters (4.6L).
z has two upstream heated oxygen sensors mounted before the three- way catalytic converters.
z the production muffler and tailpipe assembly is a one- piece design exhaust system.
Exhaust System — 3.8L Exhaust System — 4.6L (2V) SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Item Part Number Description
1 5F250 Dual converter assembly
2 5D255 Insulator bracket assembly
3 5A246 Insulator bracket, (tailpipe)
4 5D255 Insulator bracket assembly
5 5232 Muffler Klj . 1 ba
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DIAGNOSIS AND TESTING
Exhaust System
Symptom Chart
SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Symptom Chart
Condition
Possible Sources Action
z Noisy or
leaking
exhaust z
Broken or loose
clamps, hangers or
isolators.
z Punctures in the muffler
(5230).
z Broken, loose or
missing exhaust
manifold fasteners or
gaskets.
z Loose heated oxygen
or catalyst monitor
sensor. z
REPAIR as necessary.
z Exhaust system
misalignment. z
ALIGN exhaust system.
z Broken or loose
catalyst internal
components. z
LOOSEN all fasteners joining
the exhaust system and SHAKE
the system to isolate the
concern. REPAIR as necessary.
z Loss of
power z
Kinked or damaged
exhaust pipe.
z Clogged three- way
catalytic converter
(5F250).
z Foreign object in the
exhaust system. z
REPAIR as necessary. Klj . 1 ba
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REMOVAL AND INSTALLATION
Dual Converter Y-
Pipe —3.8L
Removal
NOTE: The RH and LH catalytic converters are serviceable separately.
1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. CAUTION: When repairing the exhaust system or removing exhaust components,
disconnect all heated oxygen sensors (HO2S) (9F472) and catalyst monitor sensors at
the wiring connectors to prevent damage to the sensors and wiring harnesses.
Disconnect the RH and LH HO2S connectors.
3. Disconnect the RH and LH catalyst monitor sensor connectors.
4. Remove the dual converter assembly nuts.
SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Klj . 1 ba
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5. Tighten the LH converter-
to-manifold nuts.
6. Tighten the RH converter- to-manifold nuts.
7. Connect the RH and LH HO2S connectors.
8. Connect the RH and LH catalyst monitor sensor connectors.
9. Lower the vehicle. Klj . 4 ba
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REMOVAL AND INSTALLATION
Dual Converter H-
Pipe —4.6L (2V and 4V)
Removal
NOTE: The RH and LH catalytic converters are serviced separately.
1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. CAUTION: When repairing exhaust system or removing the exhaust components,
disconnect all heated oxygen sensors (HO2S) (9F472) at the wiring connectors to prevent
damage to the heated oxygen sensors and wiring harness.
Disconnect the downstream RH and LH heated oxygen sensor connectors (9F472).
3. Disconnect the two upstream RH and LH catalyst monitor sensor connectors.
4. Remove the dual converter assembly nuts. (RH shown, LH similar.)
SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Klj . 1 ba
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