air condition FORD MUSTANG 2003 Owner's Guide

flange runout.
Symptom Chart—
Transmission (Automatic) Noise/Vibration Condition
Possible Sources Action
z Rattle— occurs
at idle or at
light
acceleration
from a stop z
Damaged engine or
transmission mounts. z
CHECK the
powertrain/drivetrain mounts
for damage. REPAIR or
INSTALL new mounts as
necessary.
z A loose front exhaust
pipe heat shield. z
REPAIR or INSTALL a new
heat shield as necessary.
z Loose inspection
plate or dust cover
plate. z
CHECK for loose bolts.
TIGHTEN to specifications.
REFER to Section 307 - 01 .
z Loose flex plate to
converter nuts. z
CHECK for loose nuts.
TIGHTEN to specifications.
REFER to Section 307 - 01 .
z Whine— pitch
increases with
vehicle speed.
Starts in first
and second
gear,
decreases or
goes away at
higher gears z
Damaged or worn low
one- way clutch.
z Damaged or worn
intermediate one- way
clutch.
z Friction elements.
z Damaged or worn
planetary or sun gear. z
INSPECT the transmission
for wear or damage. REPAIR
or INSTALL new components
as necessary. REFER to
Section 307 - 01 .
z Whine— the
pitch changes
with engine
speed z
A worn or damaged
accessory drive
component. z
CARRY OUT the Engine
Accessory Test. REPAIR or
INSTALL new components as
necessary.
z Incorrect fluid level. zCHECK that the transmission
is filled to the correct level.
ADD fluid as necessary.
REFER to Section 307 - 01 .
z Partially blocked filter. zINSPECT the filter. CLEAN or
INSTALL a new filter as
necessary. REFER to Section 307 - 01 .
z Worn or damaged
torque converter. z
CARRY OUT the torque
converter service and
replacement check. REFER
to Section 307 - 01 .
z Worn or damaged
front pump. z
INSPECT the front pump.
INSTALL a new front pump
as necessary. REFER to
Section 307 - 01 .
z Whine— pitch
changes with
vehicle speed z
Speedometer cable
or gears. z
REPAIR or INSTALL new
cables or gears as necessary.
z Whine/moan
type noise—
pitch increases
or changes
with vehicle
speed z
Damaged engine or
transmission mount. z
CHECK the
powertrain/drivetrain mounts
for damage. CARRY OUT
Powertrain/Drivetrain Mount Neutralizing in this section.
z U-joints worn or zINSPECT the U- joints for Klj . 45 ba
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damaged.
wear or damage. INSTALL
new U-joints as necessary.
REFER to Section 205 - 01 .
z Damaged or worn
differential ring and
pinion. z
INSPECT the differential ring
and pinion for damage.
CARRY OUT the Checking
Tooth Contact Pattern and
Condition of the Ring and
Pinion component test in this
section. REPAIR or INSTALL
a new differential ring and
pinion as necessary. REFER
to Section 205 - 02A for Ford
7.5 rear axles or Section 205 -
02B for Ford 8.8 integral
axles.
z Planetary gears
nicked or chipped. z
CHECK the planetary gears
for damage. INSTALL new
components as necessary.
REFER to Section 307 - 01 .
z Whistle— noise
is high pitched,
constant.
Changes in
pitch with
throttle position z
Hydraulic pressure in
the main control. z
INSPECT the main control.
REPAIR or INSTALL new
components as necessary.
REFER to Section 307 - 01 .
z Incorrect band/clutch
apply pressure. z
CARRY OUT the line
pressure tests. REPAIR or
INSTALL components as
necessary. REFER to Section 307 - 01 .
z Worn or damaged
torque converter. z
CARRY OUT the torque
converter service and
replacement check. REFER
to Section 307 - 01 .
z Clunk— occurs
when shifting
from PARK to
a drive or
reverse
position z
Damaged powertrain
mounts. z
INSPECT the powertrain
mounts for damage. INSTALL
new mounts as necessary.
z Damaged or worn
pinion bearings. z
CHECK for abnormal bearing
play or roughness. INSTALL
new bearings as necessary.
REFER to Section 205 - 02A
for Ford 7.5 rear axles or
Section 205
- 02B for Ford 8.8
integral axles.
z Worn or galled
driveshaft slip yoke
splines. z
CLEAN and INSPECT the
splines of the yoke. INSTALL
a new slip yoke as necessary.
REFER to Section 205 - 01 .
z Worn friction
elements or
excessive clutch pack
end plate play. z
INSPECT the transmission
for wear. CHECK that all end
play and clearances are
within specification. REPAIR
or INSTALL new components
as necessary. REFER to
Section 307 - 01 . Klj . 46 ba
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Pinpoint Tests
The pinpoint tests are a step-by-
step diagnostic process designed to determine the cause of a z
Bump—occurs
when shifting
from PARK to
a drive or
reverse
position.
Similar to
Clunk but with
no sound z
Initial gear
engagement. z
Acceptable condition.
z Buzz or hiss zIncorrect driveline
angles. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to Section 205 - 00 .
z Worn or damaged
main control
solenoids or valves. z
Using a transmission tester,
ACTIVATE the solenoids to
duplicate sound. INSTALL
new components as
necessary. REFER to Section 307 - 01 .
z Vibration— a
high frequency
(20–80 Hz) that
is felt through
the seat or
gear shifter.
Changes with
engine speed z
Transmission cooler
lines grounded out. z
CHECK the transmission
cooler lines. REPAIR as
necessary.
z Flexplate to torque
converter nuts loose. z
CHECK the flexplate nuts.
TIGHTEN to specification.
REFER to Section 307 - 01 .
z Fluid filler tube
grounded out. z
CHECK the fluid filler tube.
REPAIR as necessary.
z Shift cable incorrectly
routed, grounded out
or loose. z
CHECK the shift cable.
REPAIR as necessary.
Section 307 - 05 .
z Shutter or
chatter—
occurs with
light to medium
acceleration
from low
speeds or a
stop z
Electrical
inputs/outputs.
z Vehicle wiring
harness.
z Incorrect
inputs/outputs from
the powertrain control
module (PCM), digital
transmission range
(TR) sensor, brake
pedal position (BPP)
sensor, throttle
position (TP) sensor,
transmission speed
sensor (TSS), output
speed shaft (OSS)
sensor or the torque
converter clutch
(TCC). z
CARRY OUT a Torque
Converter Clutch Operation
Test. RUN on- board
diagnostics or self- test.
REFER to Section 307 - 01 .
CLEAR the DTC's, ROAD
TEST and RERUN on- board
diagnostics or self- test. Klj . 47 ba
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PINPOINT TEST B: ENGINE TICKING NOISE No
INSPECT the wheel
bearings. ADJUST or
REPAIR as necessary.
TEST the system for
normal operation.
A6 CHECK THE FRONT SUSPENSION
z
Check the front suspension for:
zBroken or loose bolts.
z Damaged springs.
z Worn or damaged upper and lower control arm
bushings.
z Loose or rough front bearings.
z Uneven tire wear.
z Are all the suspension components in satisfactory
condition? Yes
GO to
A7 .
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation. A7 RESURFACE THE FRONT BRAKE DISCS
z
CAUTION: Do not use a bench lathe to machine brake
discs.
z NOTE: Follow the manufacturer's instructions to machine the
brake discs. After machining, make sure the brake disc meets
the thickness specification.
z Refer to Brake Disc Machining in this section. Resurface the
front brake discs. Road test the vehicle.
z Is the vibration/shudder present? Yes
GO to
A8 .
No
Vehicle is OK. A8 CHECK THE REAR SUSPENSION
z
Check the rear suspension for:
zBroken or loose bolts.
z Damaged or worn springs or spring bushings.
z Worn or damaged upper and lower control arm
bushings.
z Worn or damaged trailing arms.
z Loose or rough rear bearings.
z Uneven tire wear.
z Are all the suspension components in satisfactory
condition? Yes
GO to
A9 .
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation. A9 RESURFACE THE REAR BRAKE DISC OR DRUM
z
CAUTION: Do not use a bench lathe to machine brake
discs.
z NOTE: Follow the manufacturers instructions to machine the
brake discs. After machining, make sure the brake disc meets
the thickness specification.
z Refer to Brake Disc Machining in this section. Resurface the
rear brake discs or drums. Road test the vehicle.
z Is the vibration/shudder present? Yes
CHECK the front
suspension for wear or
damage. RESURFACE
the front brake discs.
TEST the system for
normal operation.
No
Vehicle is OK.
Test Step Result / Action to Take
B1 CHECK FOR TICKING NOISE AT THE FUEL
RAIL z
Disconnect the first fuel line clip. Yes Klj . 49 ba
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Take
J1 ROAD TEST THE VEHICLE
z
NOTE: Wheel or tire vibrations felt in the steering wheel are most
likely related to the front wheel or tire. Vibration felt through the
seat are most likely related to the rear wheel or tire. This may not
always be true, but it can help to isolate the problem to the front
or rear of the vehicle.
z Test drive the vehicle at different speed ranges.
z During the road test, if the vibration can be eliminated by placing
the vehicle in neutral or is affected by the speed of the engine,
the cause is not the wheels or tires.
z Is there a vibration and noise? Yes
GO to
J2 .
No
The wheel and tires
are OK. CONDUCT a
diagnosis on other
suspect systems. J2 CHECK THE FRONT WHEEL BEARINGS
z
Check the front wheel bearings. Refer to Wheel Bearing Check in
this section.
z Are the wheel bearings OK? Yes
GO to
J3 .
No
INSPECT the wheel
bearings. ADJUST or
REPAIR as necessary.
TEST the system for
normal operation. J3 INSPECT THE TIRES
z
Check the tires for missing weights.
z Check the wheels for damage.
z Inspect the tire wear pattern. Refer to the Tire Wear Patterns
chart in this section.
z Do the tires have an abnormal wear pattern? Yes
CORRECT the
condition that caused
the abnormal wear.
INSTALL new tire(s).
TEST the system for
normal operation.
No
GO to
J4 .
J4 TIRE ROTATION
z
Spin the tires slowly and watch for signs of lateral runout.
z Spin the tires slowly and watch for signs of radial runout. Yes
GO to
J5 .
No
CHECK the wheel and
tire balance.
CORRECT as
necessary. TEST the
system for normal
operation. Klj . 56 ba
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Component Tests
Idle Air Control (IAC) Valve
1. Open the hood.
2. NOTE: Key symptom is elevated idle speed while noise is occurring.
NOTE: "Snapping" the throttle can induce the noise.
Verify the condition by operating the vehicle for a short time.
3. Inspect the IAC valve. If physical evidence of contamination exists, install a new IAC valve. GO to
M4 .
M4 INSPECT THE FRONT DRIVESHAFT
z
NOTE: Verify that the driveshaft and pinion flange index marks
are aligned.
z Inspect the front driveshaft for missing weights, damage or
undercoating.
z Inspect the U- joints and slip yoke for freedom of movement.
z Check driveshaft runout and, if necessary, check the pinion
flange runout.
z Is the driveshaft or U- joints worn or damaged? Yes
REPAIR or INSTALL a
new driveshaft as
necessary. TEST the
system for normal
operation.
No
GO to
M5 .
M5 ROAD TEST WITH THE FRONT DRIVESHAFT ONLY
z
NOTE: Index mark the driveshaft to the pinion flange and to the
output shaft before removal.
z Remove the rear driveshaft.
z Plug the transfer case with an output shaft seal plug.
z NOTE: Shift the transfer case into 4WD high so the vehicle is
driven by the front driveshaft only.
z Test drive the vehicle.
z Is the vibration gone? Yes
INSTALL and BALANCE
the rear driveshaft.
TEST the system for
normal operation.
No
GO to
M6 .
M6 ROAD TEST WITH THE REAR DRIVESHAFT ONLY
z
NOTE: Index mark the front driveshaft to the pinion flange.
z Remove the front driveshaft.
z Test drive the vehicle.
z Is the vibration gone? Yes
INSTALL and BALANCE
the front driveshaft.
TEST the system for
normal operation.
No
GO to
M7 .
M7 TRANSFER CASE TAIL SHAFT INSPECTION
z
Inspect the splines of the output shaft for wear or damage.
z Inspect the splines of the driveshaft slip yoke for wear or
damage.
z Are the splines worn or damaged? Yes
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation.
No
The transfer case is OK.
CONDUCT a diagnosis
on other suspect
systems. Klj . 63 ba
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4. While the noise is occurring, either place an EngineEAR probe near the IAC valve and the inlet
tube, or create a 6.35 mm (0.25 in)- 12.7 mm (0.50 in) air gap between the inlet tube and the
clean air tube. If the IAC valve is making the noise, install a new IAC valve.
5. Test the vehicle for normal operation.
Steering Gear Grunt/Shudder Test
1. Start and run the vehicle to operating temperature.
2. Set engine idle speed to 1200 rpm.
3. 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.
Rotate the steering wheel to the RH stop, then turn the steering wheel 90° back from that
position. Turn the steering wheel slowly in a 15° to 30° arc.
4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc.
5. Repeat the test with power steering fluid at different temperatures.
6. If a light grunt is heard or a low (50- 200 Hz) shudder is present, this is a normal steering system
condition.
7. If a loud grunt is heard, or a strong shudder is felt, fill and purge the power steering system.
Checking Tooth Contact Pattern and Condition of the Ring and Pinion
There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl
or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is
usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to
the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch
or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to
remain constant in pitch.
1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Drain the axle lubricant. Refer to Section 205 - 02A for Ford 7.5 rear axles or
Section 205 - 02B for
Ford 8.8 integral axles.
3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to Section 205 - 02A for Ford 7.5 rear axles or
Section 205 - 02B for Ford 8.8 integral axles.
4. Inspect the gear set for scoring or damage. Klj . 64 ba
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DIAGNOSIS AND TESTING
Suspension System
Inspection and Verification
1. Road test. zVerify the customer's concern by performing a road test on a smooth road.
2. Inspect tires. zCheck the tire pressure with all normal loads in the vehicle and the tires cold. For
additional information, refer to the vehicle certification (VC) label.
z Verify that all tires are sized to specification.
z Inspect the tires for incorrect wear and damage.
3. Inspect chassis and underbody. zRemove any excessive accumulation of mud, dirt or road deposits from the chassis and
underbody.
4. Inspect for aftermarket equipment. zCheck for aftermarket changes to the steering, suspension, wheel and tire components
(such as competition, heavy duty, etc.) The specifications shown in this manual do not
apply to vehicles equipped with aftermarket equipment.
5. Inspect shock absorbers. All vehicles are equipped with gas- pressurized hydraulic shock absorbers. These shock
absorbers are not adjustable or refillable and cannot be repaired.
zOil Leak: A light film of oil (weepage) on the upper portion of the shock absorber is
permissible and is a result or correct shock lubrication. Weepage is a condition in which a
film of oil accumulates on the thin tube (body) and is normally noticed due to the
collection of dust in this area. If shock absorbers exhibit this weepage condition, they are
functional units and new shock absorbers should not be installed. Leakage is a condition
in which the entire shock absorber body is covered with oil and the oil will drip from the
shock absorber onto the pavement. If condition exists:
„Make sure fluid observed is not from sources other than the shock absorber.
„ Install a new shock absorber, if necessary.
z Vehicle Sag: Many times new shock absorbers are installed in an effort to solve a vehicle
sag concern. Shock absorbers by design are hydraulic damping units only and, unlike
suspension springs, do not support any suspension loads. Therefore, installing a new
shock absorber will not correct a vehicle sag concern.
z Installment in Pairs: In the past it was recommended that new shock absorbers be
installed in pairs if one unit became unrepairable. New shock absorbers no longer need
to be installed in pairs when only one unit is not repairable.
SECTION 204-
00: Suspension System — General Information 2003 Mustang Workshop Manual Visual Inspection Chart
Mechanical Klj . 1 ba
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6. If an obvious cause for an observed or reported condition is found, correct the cause (if
possible) before proceeding to the next step.
7. If the fault is not visually evident, determine the symptom and GO to Symptom Chart .
Symptom Chart z
Front wheel bearing(s)
z Loose or damaged front or rear suspension components
z Loose, damaged or missing suspension fastener(s)
z Damaged spring(s)
z Damaged or leaking strut and spring assemblies
z Damaged or leaking shock absorber(s)
z Worn or damaged suspension bushing(s)
z Loose, worn or damaged steering system components
z Damaged axle components
Symptom Chart Condition
Possible Sources Action
z Dogtracking zExcessive rear
thrust angle. z
CHECK the wheel alignment.
ADJUST as necessary.
z Front or rear
suspension
components. z
INSPECT the front and rear
suspension system. REPAIR
or INSTALL new suspension
components as necessary.
REFER to Section 204 - 01 or
Section 204 - 02 .
z Drive axle
damaged. z
REPAIR as necessary. Refer
to the appropriate section in
Group 205 for the procedure..
z Drift/pull zUnequal tire
pressure. z
ADJUST tire pressure.
z Excessive side-to-
side difference in
caster or camber. z
CHECK the wheel alignment.
ADJUST as necessary.
z Tire forces. zROTATE tires front to rear.
z Unevenly loaded or
overloaded vehicle. z
NOTIFY the customer of
incorrect vehicle loading.
z Steering
components. z
REFER to Section 211 - 00 .
z Brake drag. zREFER to Section 206 - 00 .
z Front bottoming
or riding low z
Strut(s). zINSTALL new strut(s) as
necessary. REFER to Section 204 - 01 .
z Front coil springs
(5310). z
CHECK ride height. INSTALL
new springs as necessary.
REFER to Section 204 - 01 .
z Incorrect tire
wear z
Incorrect tire
pressure (rapid
center rib or inner
and outer edge
wear). z
ADJUST tire pressure. Klj . 2 ba
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z
wheel bearing life.
z brake cooling.
New wheels need to be installed when vehicle's wheels:
zare bent.
z are cracked.
z are dented.
z are heavily corroded.
z are leaking.
z have elongated wheel hub bolt holes.
z have excessive lateral or radial runout.
Wheel and tire assemblies are attached by six wheel nuts.
It is mandatory to use only the tire sizes recommended on the tire chart attached to the vehicle. Larger
or smaller tires can damage the vehicle, affect durability, and require changing the speedometer
calibration. Make sure wheel size and offsets match those recommended for the tire in use. 1. Inspect for signs of uneven wear that may indicate a need for balancing, rotation, front suspension alignment, damaged tie- rod, or steering components.
2. Check tires for: zcuts.
z stone bruises.
z abrasions
z blisters.
z embedded objects.
3. Tread wear indicators are molded into the bottom of the tread grooves. Install a new tire when the indicator bands become visible.
Symptom Chart Symptom Chart Condition
Possible Sources Action
z Tires show
excess wear on
edge of tread z
Underinflated tires. zADJUST air pressure
in tires.
z Vehicle overloaded. zRETURN vehicle.
NOTIFY customer of
overload condition.
z High- speed cornering. zRETURN vehicle.
NOTIFY customer of
cause of condition.
z Incorrect ride height. zSET ride height.
z Incorrect wheel alignment. zSET alignment to
specification. REFER Klj . 2 ba
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