air filter FORD MUSTANG 2003 Service Manual

·
Seals, piston damaged ·
Inspect for damage. Repair as required. ·
Check ball missing or
damaged ·
Friction elements damaged
or worn Low/Reverse Band
·
Band, servo, anchor pins
damaged or worn ·
Inspect for damage. Repair as required.
Engagement Concern: Harsh Reverse Possible Component Reference/Action
203 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, TFT sensor, EPC
solenoid ·
Carry out Self-Test; refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Carry out engagement test, EPC test
and Go To Pinpoint Test B or
Go To Pinpoint Test D . Check idle
speed. Repair as required. Clear DTCs, road test and repeat Self-
Test. 303 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Engine Driveline
·
Looseness in the
driveshaft, U- joints or the
engine mounts ·
Repair as required. 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
·
High line pressure, high
EPC pressure ·
Check pressure at line and EPC pressure taps; refer to Line
Pressure Chart for specifications. If high, check the following
components: main controls, oil filter and seal assembly. Fluid Filter and Seal
Assembly
·
Plugged or damaged ·
Install a new filter and seal assembly. ·
Filter seal damaged Main Controls
·
No. 6 shuttle ball, No. 5
check ball, manual valve,
main regulator valve stuck,
damaged or missing ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. Klj . 6 ba
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as necessary.
Incorrect Pressures
·
Low reverse clutch
pressure, low reverse
band pressure, low line
pressure ·
Check pressure at line tap; refer to Line Pressure Chart for
specifications. If pressures are low, check the following components:
main controls, pump assembly, reverse clutch assembly, reverse
servo. Fluid Filter and Seal
Assembly
·
Plugged, damaged ·
Install a new filter and seal assembly. ·
Filter seal damaged Main Controls
·
No. 6 shuttle ball,
manual valve, main
regulator valve stuck or
damaged ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Case
·
1- 2 accumulator seals
stuck or damaged ·
Inspect for damage. Repair as required. Low Reverse Servo
·
Seals (piston and cover)
damaged ·
Inspect for damage. Repair as required. ·
Servo cover retaining
ring assembled
incorrectly Pump Assembly
·
Bolts not tightened to
specification ·
Tighten bolts to specification. ·
Porosity/cross leaks/ball
missing or leaking ·
Inspect pump assembly. Install new as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
No. 1 and No. 2 seal
rings damaged ·
Inspect for damage. Repair as required. Reverse Clutch Assembly
·
Seals, piston damaged ·
Inspect for damage. Install new components as required. ·
Check ball missing or
damaged ·
Friction elements
damaged, worn ·
Return spring and piston
damaged, worn Low Reverse Band
·
Damaged, worn ·
Inspect for damage. Repair as required.
Engagement Concern: Delayed/Soft Forward Klj . 9 ba
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Possible Component Reference/Action
206 —
ELECTRICAL
ROUTINE ·
No Electrical Concerns 306 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. 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 forward clutch
pressure, low line
pressure, low EPC
pressure ·
Check pressure at line, forward clutch and EPC taps; refer to Line
Pressure Chart for specifications. If pressures are low, check the
following components: oil filter and seal assembly, main controls and
pump assembly. Fluid Filter and Seal
Assembly
·
Plugged, damaged ·
Install a new filter and seal assembly. ·
Filter seal damaged Main Controls
·
3- 4 shift valve, main
regulator valve stuck or
damaged ·
Inspect and repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Gaskets damaged ·
Inspect for damage and repair as required. Case
·
2- 3 or 1- 2 accumulator,
bore damaged or stuck ·
Inspect for damage. Repair as required. Pump Assembly
·
Bolts not tightened to
specification ·
Tighten bolts to specifications. ·
Porosity/cross leaks ·
Inspect pump assembly. Repair as required. ·
Gaskets damaged ·
Inspect for damage. Repair as required. ·
No. 3 and No. 4 seal
rings damaged ·
Inspect for damage. Repair as required. Forward Clutch
Assembly
·
Seals, piston damaged ·
Inspect for damage. Repair as required. ·
Check balls missing,
damaged ·
Inspect for mislocation, poor seating, damage. Install a new cylinder
as required. ·
Friction elements
damaged, worn ·
Check for damage. Repair as required. Klj . 10 ba
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„
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
Shift Concerns: Feel — Soft/Slipping Possible Component Reference/Action
213 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, EPC 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 D or
Go To Pinpoint Test E . Repair as required. Clear DTCs, road test and
repeat Self- Test. ·
Engine driveability concerns ·
Refer to Routine 253. 313 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Incorrect Pressures
·
Low line pressure, low EPC
pressure ·
Check pressures at line and EPC taps; refer to Line Pressure
Chart for specifications. If pressures are low or all shifts are
soft/slipping, go to main controls. If pressures are OK and a
specific shift is soft/slipping, refer to the following 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
·
Main regulator valve,
overdrive servo regulator
valve stuck, damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
EPC solenoid stuck or
damaged ·
Inspect for damage and contamination. Carry out EPC tests in
Routine 213. Repair as required. Case
·
1- 2 accumulator stuck or
damaged ·
Inspect for damage. Repair as required. Filter and Seal Assembly
·
Filter plugged, damaged ·
Inspect for damage. Install a new filter as required. ·
Seal damaged or cut ·
Inspect for damage. Replace as required. Klj . 13 ba
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X = pressure applied Adjust the digital TR sensor as necessary.
Incorrect Pressures
·
Low reverse clutch pressure,
low reverse band pressure, low
line pressure
z Forward Off, Intermediate
Off, Direct X
z Forward Off, Intermediate
X, Direct Off
z Forward Off, Intermediate
X, Direct X
z Forward X, Intermediate
Off, Direct X
z Forward X, Intermediate X,
Direct Off
z Forward X, Intermediate X,
Direct X
z Forward X, Intermediate
Off, Direct Off ·
Check for which pressures are on and refer to Band/Clutch
Application Chart 601 and corresponding routines.
„ 324, 301
„ 325, 301
„ 323, 324, 325, 301
„ 324
„ 325
„ 323, 324, 325
„ Refer to appropriate mechanical diagnosis. Mechanical
·
Bands, clutches or seals
damaged or worn ·
Refer to Transmission Disassembly and Assembly.
Shift Concerns: No Manual 1st Gear Possible Component Reference/Action
216 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses, PCM,
shift solenoids, 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 A or
Go To Pinpoint Test C . Repair as required. Clear
DTCs, road test and repeat Self- Test. 316 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Cable, 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. Incorrect Pressures
·
Low reverse clutch pressure,
low reverse band pressure, low
line pressure, low EPC
pressure ·
Check pressure at line and EPC pressure taps; refer to Line
Pressure Chart for specifications. If pressures are low, check
the following components: oil filter and seal assembly, main
controls, reverse clutch assembly and reverse servo
assembly. Fluid Filter and Seal Assembly
·
Plugged or damaged ·
Install a new filter and seal assembly. Klj . 15 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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mechanism damaged
Main Controls
·
Manual valve stuck or
damaged ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications.
Other Concerns: External Leaks Possible Component Reference/Action
252 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, sensor
seals leaking (digital TR, OSS,
vehicle speed sensor VSS, if
equipped, or transmission connector) ·
Inspect for leakage and repair as required. 352 —
HYDRAULIC/MECHANICAL ROUTINE Case
·
Case vent, case porosity, case
cracked ·
Check the vent for free breathing. Check the fluid level.
Check the transmission for overheat conditions. Repair
as required. Seals/Gaskets
·
Leakage at gaskets, seals, etc. (refer
to external sealing illustration for
potential leak locations) ·
Remove all traces of lubricant on exposed surfaces of
the transmission. Check the vent for free breathing.
Operate the transmission at normal temperatures and
perform fluid leakage check. Repair as required. Other
·
Cooler fitting, cooler lines pressure
tap, converter drain plug, band
anchor pins ·
Locate the source of the leak. Repair as required.
Other Concerns: Poor Vehicle Performance Possible Component Reference/Action
253 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, shift solenoids,
digital TR sensor, torque
converter clutch (TCC) solenoid,
transmission fluid temperature
(TFT) 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 A ,
Go To Pinpoint Test B or
Go To Pinpoint Test C . Repair as required. Clear codes, road test and
repeat Self- Test. Also refer to Routines 241/341 Torque
Converter Operation Concern: Always Applied. ·
Engine driveability concerns ·
Inspect air intake/air filter system. Check the fuel system
and fuel pressure. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual. Inspect the
exhaust system for restriction. Refer to Section 309 - 00 .
353 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR Sensor Klj . 27 ba
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GENERAL PROCEDURES
Transmission Fluid Cooler —
Backflushing and Cleaning
1. 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.
Conduct backflushing with a suitable torque converter/fluid cooler cleaner. Test your equipment
to make sure that a vigorous fluid flow is present before proceeding. Install a new filter in the
flush equipment if flow is weak or contaminated.
2. To aid in attaching the cleaner to the transmission steel cooler lines, connect two additional rubber hoses to the transmission end of the steel transmission cooler lines as described below.
zConnect the cleaner tank pressure line to the steel transmission cooler return line
(longest line).
z Connect a tank return hose to the steel transmission cooler pressure line (shorter line).
Place the outlet end of this hose in the solvent tank reservoir.
3. Turn on solvent pump and allow the solvent to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system).
4. Switch off the solvent pump and disconnect the solvent pressure hose from the transmission cooler return line.
5. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all solvent is removed.
6. Remove the rubber return hose from the remaining steel cooler line.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 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
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3.
CAUTION: If installing a new filter, and the seal remains in the main control bore,
carefully use a small screwdriver to remove the seal. Use care not to damage the main
control bore.
NOTE: If transmission is being repaired for a contamination- related failure, use a new filter and
seal. The filter may be reused if no excessive contamination is present.
Install a new fluid filter and seal as required.
4. Position the pan magnet into the transmission fluid pan.
5. NOTE: The transmission fluid pan gasket is reusable. Clean and inspect for damage; if not
damaged, the gasket should be reused.
Install the transmission fluid pan and gasket. 1. Position the transmission fluid pan and gasket.
2. Install the transmission fluid pan bolts. Klj . 4 ba
52003 Mustang Workshop Manual
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