air condition FORD MUSTANG 2003 Service Manual

to
Section 204 - 00 .
z Incorrect tire rotation
intervals. z
ADVISE customer of
condition. ROTATE
tires.
z Tires show
excess wear in
center of tread z
Tires overinflated. zADJUST air pressure.
z Other excessive
tire wear
problems z
Incorrect tire rotation
intervals. z
ADVISE customer of
condition. ROTATE
tires.
z Incorrect tire pressure. zADJUST pressure.
z Loose or leaking shock
absorbers. z
TIGHTEN or INSTALL
new shock absorbers
as necessary.
z Incorrect wheel alignment. zSET alignment to
specification. REFER
to Section 204 - 00 .
z Loose, worn or damaged
suspension components. z
REFER to Section 204 - 00 .
z Wheel and tire assembly
out of balance. z
BALANCE wheel and
tire assembly.
z Excessive lateral or radial
runout of wheel. z
REFER to Section 100 - 04 .
z Wobble or
shimmy z
Damaged wheel bearings. zREFER to Section 204 - 00 .
z Loose or damaged
suspension components. z
REFER to Section 204 - 00 .
z Bent wheel. zINSTALL a new wheel
as necessary.
z Damaged tire. zINSTALL a new tire as
necessary.
z Loose wheel nuts. zTIGHTEN to
specification.
z High- speed
shake z
Wheel hub face/pilot/bolt
circle runout.
z Tires/wheels.
z Wheel bearings.
z Suspension/steering
linkage.
z Engine.
z Transmission.
z Brake discs/imbalance. z
REFER to Section 100 - 04 .
z Vehicle vibration zDriveline — engine.
z Tires. z
REFER to Section 100 - 04 . Klj . 3 ba
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Inspection and Verification
Certain axle noise or vibration symptoms are also common to the engine, transmission, wheel
bearings, tires, and other parts of the vehicle. For this reason, be sure that the cause of the trouble is
in the axle before disassembling, adjusting or repairing the axle. Refer to
Section 100 - 04 .
Certain driveshaft vibration symptoms are common to the front engine accessory drive (FEAD), the
engine, transmission or tires. Be sure the cause of the concern is the driveshaft before repairing or
installing a new driveshaft. Refer to Section 100 - 04 .
Certain symptoms may be caused by Traction- Lok® differentials (4026). Check the vehicle certification
label and axle identification tag to determine the type of differential. Refer to Section 100 - 01 .
Noise Acceptability
NOTE: A gear-driven unit will produce a certain amount of noise. Some noise is acceptable and
audible at certain speeds or under various driving conditions such as a newly paved blacktop road.
Slight noise is not detrimental to the operation of the axle and is considered normal.
With the Traction- Lok® differential axle, slight chatter noise on slow turns after extended highway
driving is considered acceptable and has no detrimental effect on the locking axle function.
Universal Joint (U- Joint) Inspection
Place the vehicle on a frame hoist and rotate the driveshaft (4602) by hand. Check for rough operation
or seized U- joints. Install a new U- joint if it shows signs of seizure, excessive wear, or incorrect
seating. Refer to Section 205 - 01 .
Analysis of Leakage
Clean up the leaking area enough to identify the exact source. An axle leak can be caused by the
following. zAxle lubricant level is too high.
z Worn or damaged axle shaft seals or differential seals.
z Differential housing is cracked.
z Flange yoke seat is worn or damaged.
z Pinion flange is scored or damaged.
z Axle cover is not sealed.
z Vent is plugged. Klj . 2 ba
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Repair the axle as necessary. Make sure the axle lubricant is at the correct level. Refer to
Specifications in this section.
Axle Vent
NOTE:
If a plugged vent cannot be cleared, install a new one.
A plugged vent will cause excessive seal lip wear due to internal pressure buildup. If a leak occurs,
check the vent. Make sure the vent hose is not kinked. Remove the hose from the vent nipple and
clear the hose of any foreign material. While the hose is removed, pass a length of mechanics wire in
and out of the vent to clean it. Connect the hose when done.
Flange Yoke Seal
Leaks at the axle drive pinion seal originate for the following reasons:
zSeal was not correctly installed.
z Poor quality seal journal surface.
Any damage to the seal bore (dings, dents, gouges, or other imperfections) will distort the seal casing
and allow leakage past the outer edge of the axle drive pinion seal.
The axle drive pinion seal can be torn, cut, or gouged if it is not installed carefully. The spring that
holds the axle drive pinion seal against the pinion flange may be knocked out and allow leakage past
the lip.
The rubber lips can occasionally become hard (like plastic) with cracks at the oil lip contact point. The
contact point on the pinion flange may blacken, indicating excessive heat. Marks, nicks, gouges, or
rough surface texture on the seal journal of the pinion flange will also cause leaks.
When a seal leak occurs, install a new seal and check the vent and the vent hose to make sure they
are clean and free of foreign material.
Axle Shaft Seals
Axle shaft oil seals are susceptible to the same kinds of damage as axle drive pinion seals if incorrectly
installed. The seal bore must be clean and the lip handled carefully to avoid cutting or tearing it. The
axle shaft journal surface must be free of nicks, gouges, and rough surface texture.
Differential Seals
Refer to Section 205 - 02A or
Section 205 - 02B .
Analysis of Vibration WARNING: A vehicle equipped with a Traction- Lok® differential will always have both
wheels driving. If only one wheel is raised off the floor and the rear axle is driven by the engine,
the wheel on the floor could drive the vehicle off the stand or jack. Be sure both rear wheels are
off the floor.
Few vibration conditions are caused by the rear axle. On a vibration concern, follow the diagnosis
procedure in Section 100 - 04 unless there is a good reason to suspect the axle.
Tires Klj . 3 ba
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crayon or chalk.
6. While holding the crayon or chalk against the tire, rotate the wheel slowly in the opposite direction until the feeling of driving the rear axle is encountered again.
7. Measure the length of the crayon or chalk mark on the tire. zIf the length of the mark is 25.4 mm (1 inch) or less, the rear axle backlash is within
allowable limits.
z If the chalk mark is greater than 25.4 mm (1 inch), check for these conditions:
„Elongation of the differential pinion shaft and holes in the differential case (4204).
„ Missing differential pinion thrust washer (4230) or differential side gear thrust
washer (4228).
„ Galling of the differential pinion shaft (4211) and bore.
„ Excessive ring gear and pinion backlash. Follow the procedure for the type of rear
axle to check backlash.
Axle Shaft Bearing Noise
Axle bearing shaft noise is similar to gear noise and differential pinion bearing whine. Axle shaft
bearing noise will usually distinguish itself from gear noise by occurring in all driving modes (drive,
coast, and float), and will persist with the transmission in NEUTRAL while the vehicle is moving at the
speed in which the concern is occurring. If the vehicle makes this noise, remove the suspect axle
shaft, install a new bearing and a new axle seal. Re- evaluate the vehicle for noise before removing any
internal components.
Bearing Rumble
Bearing rumble sounds like marbles being tumbled. This condition is usually caused by a
worn/damaged wheel bearing. The lower pitch is because the wheel bearing turns at only about one-
third of the driveshaft speed. Wheel bearing noise also may be high- pitched, similar to gear noise, but
will be evident in all four driving modes.
Symptom Chart
Symptom Chart Condition
Possible Sources Action
z Traction- Lok®
does not work in
snow, mud or on
ice z
Differential. zCARRY OUT the Traction-
Lok® Differential Operation
Check in this section. REPAIR
as necessary. REFER to
Section 205 - 02A or
Section 205 - 02B .
z Lubricant leaking
from the pinion
seal, axle shaft oil
seals z
Vent.
z Damage in the
seal contact area
or damaged or
worn seal. z
CLEAN the axle housing vent.
z INSTALL a new seal if
damage is found.
z Differential side
gears/pinion
gears are scored z
Insufficient
lubrication. z
INSTALL new gears. REFER
to Section 205 - 02A or
Section 205 - 02B . FILL the axle to
specification.
z Incorrect or
contaminated z
INSTALL new gears. REFER
to Section 205 - 02A or
Section Klj . 10 ba
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GENERAL PROCEDURES
Axle Housing Casting Porosity (Holes in Casting) Repair
CAUTION: To keep the axle's sound characteristics, do not disassemble the carrier.
NOTE: Casting porosity is a condition where occasionally gas bubbles will form during the casting
process leaving small pockets in the metal that will cause the axle housing to leak.
1. To fill small pockets, peen in a small amount of body lead.
2. Seal the pocket. zUse epoxy sealer meeting Ford specification M- 3D35A(E).
3. To fill large pockets, drill and tap a shallow hole for a small setscrew. Install the setscrew and seal it.
zUse epoxy sealer meeting Ford specification M- 3D35A(E).
SECTION 205-
00: Driveline System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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in the brake master cylinder reservoir are also indicators of system concerns.
If a wheel is locked and the vehicle must be moved, open a bleeder screw at the locked wheel (1007)
to let out enough fluid to relieve the pressure. Close the bleeder screw. This bleeding operation may
release the brakes but will not correct the cause of trouble. If this does not relieve the locked wheel
condition, repair the locked components before proceeding.
Inspect all hoses and connections. All unused vacuum connectors should be capped. Make sure
hoses and their connections are correctly secured and in good condition with no holes, soft or
collapsed areas.
Non-
Pressure Leaks
The only part of the brake system that could have a brake fluid loss that does not appear when the
system is under pressure is the brake master cylinder reservoir area. Brake fluid loss can be caused
by a missing or poorly- fitted brake master cylinder filler cap (2162), a punctured or otherwise damaged
brake master cylinder reservoir, a missing or damaged brake master cylinder filler cap gasket, or by
missing, damaged or poorly- fitted sealing grommets between the brake master cylinder (2140) and the
brake master cylinder reservoir.
The brake master cylinder reservoir grommets are not separately serviceable and must be installed
new as part of a new brake master cylinder reservoir.
Install a new flexible brake hose if it shows signs of softening, cracking or other damage.
When installing a new brake hose, position the hose to avoid contact with other vehicle components.
Road Test
Perform a road test to compare actual vehicle braking performance with the performance standards
expected by the driver. The ability of the test driver to make valid comparisons and detect performance
deficiencies will depend on experience.
The driver should have a thorough knowledge of brake system operation and accepted general
performance guidelines in order to make good comparisons and detect performance problems.
Select a road that is reasonably smooth and level. Gravel or bumpy roads are not suitable because the
surface does not allow the tires to grip the road equally. Avoid crowned roads.
A key factor in evaluating brake concerns is the deceleration rate. This varies from vehicle to vehicle
and with changes in operating conditions. It is evident how well the brakes are working after just a few
applications.
Avoid locking the brakes. Locked brakes are not an indication of braking efficiency.
Visual Inspection Chart Mechanical Electrical
z
Brake master cylinder
z Brake caliper piston
z Brake discs
z Brake pads z
Parking brake switch
z Damaged or corroded wiring harness
z Brake master cylinder fluid level switch Klj . 2 ba
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not machine a new brake disc.
7. For vehicles with a two- piece hub and brake disc assembly:
z Match-mark before disassembly.
z Remove the brake disc.
z Using a die grinder with a mild abrasive (Scotch Brite® type), remove any rust or
corrosion from the hub and brake disc mounting surfaces.
z Align the match- marks and reinstall the brake disc on the hub.
8. CAUTION: Do not use a bench lathe to machine brake discs.
NOTE: The depth of cut must be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter
cuts will cause heat and wear. Heavier cuts will cause poor brake disc surface finish.
Using on- vehicle brake lathe, machine the brake discs. Follow the manufacturer's instructions.
After machining, make sure the brake disc still meets the thickness specification.
9. Using a dial indicator, verify that the brake disc lateral runout is now within vehicle specification.
10. Remove any metal chips.
11. Remove the hub adapter.
12. Remove any remaining metal chips from the machining operation.
13. CAUTION: Do not carry out this step on rear drum- in-hat brake discs.
For vehicles with a two- piece hub and a non drum- in-hat brake disc assembly:
z Remove the brake disc from the hub.
z Remove any remaining metal chips from hub and brake disc mounting surfaces and from
the ABS sensor.
z Apply High Temperature Nickel Anti- Seize Lubricant F6AZ-9L494-AA to the mounting
surfaces.
z Using the match- marks, mount the brake disc on the hub.
14. Install the caliper and check brake operation.
Symptom Chart Symptom Chart
Condition
Possible Sources Action
z The Brakes Pull or
Drift z
Tire air pressure.
z Wheel alignment.
z Brake pads.
z Brake components.
z Suspension
component. z
Go To Pinpoint Test A .
z The Red Brake
Warning Indicator Is z
Instrument cluster.
z Circuit. z
Go To Pinpoint Test B . Klj . 4 ba
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PINPOINT TEST F: HYDRO-
BOOST ERRATIC OPERATION, STICKS,
BINDS OR GRABS z
Check accessory drive belt tension and
condition. Refer to Section 303 - 05 .
z Is the accessory drive belt OK? Yes
GO to
E3 .
No
INSTALL a new accessory drive belt.
REFER to Section 303 - 05 .
E3 CHECK POWER STEERING HOSES
z
Check power steering pressure hoses, power
steering gear pressure hoses and power
steering return hose for cracks or leaks.
z Do power steering pressure hose, power
steering gear hose and power steering
return hose check OK? Yes
GO to
E4 .
No
INSTALL new hoses as necessary.
REFER to Section 211 - 00 .
E4 CHECK BRAKE PEDAL LINKAGE
z
Check brake pedal linkage for binding or
sticking operation.
z Does pedal linkage check OK? Yes
GO to
E5 .
No
INSTALL new pedal linkage as necessary.
REFER to Section 206 - 06 .
E5 CHECK POWER STEERING PUMP SPEED
z
Check engine idle speed against
specifications.
z Is engine idle speed OK? Yes
GO to
E6 .
No
SET engine idle speed to specification.
REFER to Powertrain Control/Emissions
Diagnosis (PC/ED) manual. E6 CHECK FOR PLUGGED RETURN HOSE
z
NOTE: The return hose from the oil cooler to
the power steering reservoir has an in- line
filter in the hose.
z Disconnect power steering return hose from
power steering fluid cooler and power
steering pump reservoir.
z Pass air through hose from the oil cooler end.
z Is hose plugged? Yes
INSTALL a new power steering return
hose.
No
GO to
E7 .
E7 CHECK POWER STEERING PUMP FLOW
AND RELIEF z
Test power steering pump for correct flow
and relief pressure. Refer to Section 211 - 00 .
z Is power steering pump operating
correctly? Yes
INSTALL a new power brake hydro-
boost
unit. REFER to Section 206 - 07 .
No
INSTALL a new power steering pump.
REFER to Section 211 - 02 .
Test Step Result / Action to
Take F1 CHECK SUPPLY HOSE
z
Check for obstructions in power steering return hose and Yes Klj . 11 ba
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PINPOINT TEST G: HYDRO-
BOOST BRAKE SYSTEM OPERATION
SUSPECT connections between the power steering pump reservoir and
between the power steering pump reservoir and the hydro-
boost
power brake booster.
z Are there any obstructions? REMOVE
obstructions or
INSTALL a new
hose.
No
GO to
F2 .
F2 CHECK BOOSTER OPERATION
z
Have an assistant check the fluid in the power steering pump
reservoir while rapidly applying the brake pedal approximately one
inch.
z Does the fluid show any movement or spouting? Yes
System OK.
No
INSTALL a new
hydro-boost
assembly. Test Step Result / Action to Take
G1 CHECK BASIC OPERATION
z
Key in OFF position.
z Press and release brake pedal several times to deplete all
hydraulic pressure from the hydro- boost power brake
booster.
z Press and hold brake pedal with light pressure.
z Key in START position.
z Does the brake pedal fall slightly and hold, and is less
pressure now required to hold brake pedal at the new
position? Yes
Hydro-
boost is OK.
No
GO to G2 .
G2 CHECK FOR HYDRAULIC BRAKE LEAK
z
With engine running, press and release brake pedal several
times.
z Hold brake pedal down with medium pressure, 34- 47 Nm
(25- 35 lb- ft).
z Does brake pedal move toward floor? Yes
GO to
G3 .
No
GO to G4 .
G3 CHECK FOR LEAKS —
BRAKE FLUID LINES z
Check for leaks at brake lines, including brake master
cylinder and brake hose.
z Do components check OK? Yes
COMPLETE master cylinder
By-
Pass Condition Test in
this section.
No
INSTALL new hoses and
lines as necessary. G4 CHECK HYDRO-
BOOST CONNECTIONS z
Clean the hydro- boost power brake booster, power steering
pressure hose, power steering gear pressure hose and
power steering return hose and connection.
z Start engine and run at idle.
z Check hose connections for leakage.
z Do hose connections check OK? Yes
GO to
G5 .
No
REPAIR or INSTALL new
hose and connections as
necessary. G5 CHECK FOR HYDRO-
BOOST LEAK Klj . 12 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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