air suspension FORD MUSTANG 2003 Service Manual

DESCRIPTION AND OPERATION
Rear Drive Halfshafts
The rear wheel drive halfshaft system consists of and operates as follows:
zHalfshafts (4K138) transmit engine torque from the rear axle housing to the rear wheels.
z Halfshafts rotate at approximately one- third the speed of a driveshaft and do not contribute to
rotational vibration disturbances.
z A constant velocity (CV) joint is a mechanism for transmitting uniform torque and rotary motion
while operating through a range of angles.
z CV joints at both inboard (differential) and outboard (wheel) ends provide operating
smoothness.
z The inboard CV joints are plunge- type joints that provide the axial movement necessary to
affect shaft length changes.
z The outboard CV joints have a higher angle capability than the inboard CV joints to
accommodate suspension travel.
z Inboard and outboard CV joints connect to a splined shaft.
z A driveshaft bearing retainer circlip retains the splined inboard CV joint to the differential side
gear. Install a new circlip every time you remove the halfshaft from the vehicle.
z A rear axle wheel hub retainer secures the interconnecting shaft and outboard CV joint to the
rear hub.
z The lubed-for- life CV joints use special CV joint grease. They require no periodic lubrication.
z To separate the halfshaft from the rear hub, press the outboard CV joint from the rear hub.
z To separate the halfshaft from the differential, apply a load to the back face of the inboard CV
joint assembly to overcome the circlip.
z The halfshaft assemblies are not repairable. Install a new assembly if worn/damaged.
SECTION 205-
05: Rear Drive Halfshafts 2003 Mustang Workshop Manual Klj . 1 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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Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center
after a turn or the steering correction is completed.
Shimmy
Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel
resulting from large, side-
to-side (lateral) tire/wheel movements.
Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire
contacts pot holes or irregularities in the road surface.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel
corrections to maintain a straight path down a level road.
Symptom Chart
Symptom Chart Condition
Possible Sources Action
z Hard Steering or
Lack of Assist z
Seized lower steering
column shaft U- joints. z
INSTALL a new lower
steering column shaft.
REFER to Section 211 - 04 .
z Damaged, fractured
steering column
bearing(s). z
REPAIR the steering
column. REFER to
Section 211 - 04 .
z Power steering pump. zGO to Pump Flow and
Pressure Test
Component Test in
this section.
z Suspension
components. z
REFER to Section 204 - 00 for suspension
system diagnosis and
testing.
z Steering gear internal
leakage. z
GO to Pump Flow and
Pressure Test
Component Test in
this section.
z Excessive Steering
Pump Noise z
Power steering pump. zGO to Pump Flow and
Pressure Test
Component Test in
this section.
z Excessive Steering
Wheel Play z
Damaged, loose, or
worn tie- rod end
(3A130). z
GO to the Steering
Linkage Component
Test.
z Loose, worn or
damaged front wheel
spindle tie- rod (3280). z
GO to the Tie- Rod
Articulation Torque
Component Test.
z Damaged/worn
steering gear. z
INSTALL a new
steering gear. REFER
to Section 211 - 02 .
z Loose, worn or
damaged steering z
INSTALL new
steering column Klj . 5 ba
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·
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. Verify Correct Shift Scheduling
and Engagements
·
See Reference/Action ·
Go to the appropriate diagnostic routines. Torque Converter Clutch Always
Applied
·
See Reference/Action ·
Go to Hydraulic/Mechanical Routine 241/341. Torque Converter Clutch
·
Damaged ·
Inspect torque converter. Install a new converter as outlined.
Other Concerns: Noise/Vibration — Forward Or Reverse Possible Component Reference/Action
254 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 354 —
HYDRAULIC/MECHANICAL ROUTINE For Noises/Vibrations That Change With Engine
Speed
·
Converter components/balance weight ·
Locate source of disturbance. Repair as
required. ·
Fluid level (low) pump cavitation ·
Pump assembly ·
Engine drive accessories ·
Cooler lines grounding out ·
Flexplate For Noises/Vibrations That Change With Vehicle
Speed
·
Engine mounts loose or damaged ·
Locate source of disturbance and repair as
required. ·
Driveline concerns:
„ U-joints
„ Rear axle
„ Suspension
„ Modifications
1st Gear: „Low one- way clutch
„ Gearset
„ Friction elements ·
Refer to the following 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
„ Torque Converter Cycling 242/342 ·
2nd Gear:
„ Intermediate one- way clutch
„ Intermediate clutch piston bleed hole out of Klj . 28 ba
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z
Check that the vehicle is on level ground.
z If the vehicle is equipped with air suspension, make sure that the switch is on.
2. NOTE: The vertical wall or screen must be a minimum of 2.4 meters (8 feet) wide.
Park the vehicle on a level surface approximately 7.6 meters (25 feet) from the vertical wall or
screen directly in front of it.
3. NOTE: The center of the lamp is marked by a 3 mm (0.12 in) circle on the headlamp lens.
Mark a horizontal reference line on the vertical wall or screen. 1. Measure the center of the headlamp height to ground and record.
2. Make a 2.4 meter (8 foot) horizontal mark (masking tape) on the vertical wall or screen at the same distance from the ground as previously recorded.
4. NOTE: This procedure should be done in a dark environment to effectively see the headlamp
beam pattern.
Turn on the low beam headlamps to illuminate the wall or screen and open the hood.
5. NOTE: For SAE type headlamps, the appearance of the beam pattern may vary between
vehicles.
On the wall or screen, locate the high intensity area of the beam pattern. Place the top edge of
the high intensity zone even with the horizontal reference line.
VOR type headlamps 6. NOTE: The appearance of the VOR beam pattern may vary between vehicles.
Identify at the top edge of this high intensity area a distinct horizontal cutoff in the beam pattern.
If the top edge of this cutoff is not even with the horizontal reference line, the headlamp beam will need to be adjusted. Klj . 2 ba
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DESCRIPTION AND OPERATION
Frame Assembly
Underbody misalignment can affect front and rear wheel alignment, the operation of the suspension
parts and drivetrain operation. Window glass cracks, door and window opening concerns, and air or
water leaks at the doors are often caused by improperly tightened bolts and body misalignment.
Every structural member and outer panel is designed to offer the maximum protection in the event of a
collision.
SECTION 502-
00: Frame and Body Mounting 2003 Mustang Workshop Manual Klj . 1 ba
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GENERAL INFORMATION

INTRODUCTION

In the past, when cars were simpler, diagrams were simpler. All components were connected by wires, and
diagrams seldom exceeded 4 pages in length. Today, some wiring diagrams require more than 16 pages. It
would be impractical to expect a service technician to trace a wire from page 1 across every page to page 16.
Components shown with a dashed line instead of a solid line indicate not all circuits are shown in this
particular diagram (circuits shown in system diagrams are typically applicable to that system only). The
remaining circuits connected to that component will be shown in the appropriate system that they apply to.
Today, the wiring diagram necessary to support a given repair procedure is included within that article or a
link is provided to the appropriate SYSTEM WIRING DIAGRAM article. For example, the wiring diagram
for a Ford EEC-IV system may be included in ENGINE PERFORMANCE and WIRING DIAGRAMS
articles for Ford Motor Co. The wiring diagram for a cruise control system may be included in
ACCESSORIES & EQUIPMENT section for the specific vehicle manufacturer, and the wiring diagram for
an anti-lock brake system may be included in BRAKES and WIRING DIAGRAMS for the specific
manufacturer.
WIRING DIAGRAMS cont ains all wiring diagrams not in cluded in STARTING & CHARGING
SYSTEMS and ACCESSORIES & EQUIPMENT. Th is includes: Data Link Connectors, Ground
Distribution, Power Distribution, Engine Performance, Electri c Cooling Fans, Anti-Lock Brakes, Electronic
Suspension and Electronic Steering wiring diagrams. The Data Link Conne ctors wiring diagrams show the
circuits by which the various on-board computers exchange information, and the diagnostic connectors used
for diagnosis and their location. The Ground Distribution wi ring diagrams show all vehicle ground points,
their location, and the components co mmon to those ground points. The Po wer Distribution wiring diagrams
show the power feed circuits and the components common to those power feeds.
Wiring diagrams used to support the information in ACCESSORIES & EQUIPMEN T are drawn in a "top-
down" format. The diagrams are drawn with the power source at the top of the diagram and the ground point
at the bottom of the diagram. Component locations are identified on the wiring diagrams. Any wires that do
not connect directly to a component are identifi ed on the diagram to indicate where they go.


WIRING DIAGRAM COLOR ABBREVIATIONS
COLOR ABBREVIATIONS
ColorNormalOptional

GENERAL INFORMATI


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Camshaft Position (CMP) SensorEngine Performance
Central Control ModuleAnti-Theft System
ClockspringAir Bag Restraint System; Cruise Control
Systems; Steering Column Switches
Clutch Pedal Position SwitchStarters
Clutch Start SwitchStarters
Combination MeterAnalog Instrument Panels
Constant Control Relay Module (CCRM)Engine Performance; Electric Cooling Fans
Convenience CenterPower Distribution; Illu mination/Interior Lights
Convertible Top MotorPower Convertible Top
Convertible Top SwitchPower Convertible Top
Crankshaft Position (CKP) SensorEngine Performance
Cruise Control ModuleCruise Control Systems
Cruise Control SwitchCruise Control Systems
Condenser Fan Relay(s)Electric Cooling Fans
Data Link Connector (DLC)Engine Performance
Daytime Running Lights ModuleDaytime Running Lights; Exterior Lights
Defogger RelayRear Window Defogger
Diagnostic Energy Reserve Module (DERM)Air Bag Restraint System
Discriminating Sensor (Air Bag)Air Bag Restraint System
DistributorEngine Performance
Door Lock ActuatorsPower Door Locks; Remote Keyless Entry
Door Lock Relay(s)Power Door Locks
Electrochromic MirrorPower Mirrors
Electronic Level Control (ELC) Height SensorElectronic Suspension
Electronic Level Control (ELC) ModuleElectronic Suspension
Engine Coolant Temper ature (ECT) Sending UnitAnalog Instrument Panels
Engine Coolant Temperature (ECT) SensorEngine Performance
Engine Control ModuleEngine Performance; Ge nerators & Regulators;
Starters
ETACS ECUWarning Systems; Power Windows; Remote Keyless Entry
Evaporative (EVAP) Emissions CanisterEngine Performance
EVAP Canister Purge SolenoidEngine Performance
EVAP Canister Vent SolenoidEngine Performance
Exhaust Gas Recirculation (EGR) ValveEngine Performance
Fuel Tank Vacuum SensorEngine Performance
Fog LightsHeadlight Systems; Daytime Running Lights
Fog Light RelayHeadlight Systems; Daytime Running Lights
Fuel Door Release SolenoidPower Fuel Door Release
Fuel Gauge Sending UnitAnalog Instrument Panels
Fuel InjectorsEngine Performance
Fuel PumpEngine Performance
Fuel Pump RelayEngine Performance; Power Distribution


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Fuse/Relay BlockPower Distribution
Fusible LinksPower Distribution; Generators & Regulators;
Starters
GeneratorGenerators & Regulators; Engine Performance;
Power Distribution
Generic Electronic Module (GEM)Body Control Modules; Electronic Suspension
Glow Plug RelayEngine Performance
Glow PlugsEngine Performance
GroundsGround Distribution
Headlight Door ModuleHeadlight Doors
Headlight RelayHeadlight Systems; Daytime Running Lights
HeadlightsHeadlight Systems; Daytime Running Lights
Heated Oxygen Sensor(s) (HO2S)Engine Performance
Heated Windshield Control ModuleHeated Windshields
Height SensorElectronic Suspension
HornsSteering Column Switches
Horn RelaySteering Column Switches
Idle Air Control (IAC) Motor/ValveEngine Performance
Ignition Coil(s)Engine Performance
Ignition Key Lock CylinderAnti-Theft System
Ignition ModuleEngine Performance
Ignition SwitchPower Distribution; Engine Performance; Generators & Regulators; Starters
Illuminated Entry ModuleIllumination/Interior Lights
Illumination LightsIllumination/Interior Lights
Impact SensorAir Bag Restraint System
Inertia Fuel Shutoff SwitchEngine Performance
Inhibit RelayStarters
Instrument ClusterAnalog Instrument Panels
Intake Air Temperature (IAT) SensorEngine Performance
Interior LightsIllumination/Interior Lights
Interlock SwitchStarters
Junction BlockPower Distribution
Keyless Entry ReceiverRemote Keyless Entry
Key Reminder SwitchStarters
Knock SensorEngine Performance
Lamp Control ModuleExterior Lights
License Plate LampExterior Lights
Lighting Control ModuleLighting Control Modules; Anti-Theft System; Daytime Running Lights; Headlight Systems
Lower RelayPower Convertible Top
Malfunction Indicator Light (MIL)Engine Performance; Instrument Panels
Manifold Absolute Pr essure (MAP) SensorEngine Performance
Mass Airflow (MAF) SensorEngine Performance


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SIR Coil Assembly (Clockspring)Air Bag Restraint System
Slip Ring (Clockspring)Air Bag Restraint System; Steering Column Switches
SRS Control ModuleAir Bag Restraint System
Starter MotorStarters
Starter Interrupt RelayStarters
Starter SolenoidStarters
Starter RelayStarters
Steering Wheel Position SensorAnti-Lock Brakes
StoplightsExterior Lights
Stoplight SwitchEngine Performance; Cruise Control Systems;
Anti-Lock Brakes
Sun Roof ECUPower Sun Roof
Sun Roof MotorPower Sun Roof
Sun Roof Position SensorPower Sun Roof
TaillightsExterior Lights
Throttle Position (TP) SensorEngine Performance
Torque Converter Clutch Solenoid/SwitchEngine Performance
Traction Control SwitchAnti-Lock Brakes
Trailer Tow ConnectorExterior Lights
Trailer Tow RelayExterior Lights
Transmission/TransaxleEngine Performance
Transmission Control Module (TCM)Engine Performance; Starters
Transmission Range SensorStarters; Back-Up Lights; Engine Performance
Transmission Range SwitchBack-Up Lights; Engine Performance; Anti-Theft
System
Turn Signal FlasherExterior Lights
Turn Signal LightsExterior Lights
Twilight Sentinel SwitchHeadlight Systems; Daytime Running Lights
Vapor Canister Le ak Detection PumpEngine Performance
Vehicle Control Module (VCM)Engine Performance
Vehicle Dynamic ModuleElectronic Suspension
Vehicle Speed Control ServoCruise Control Systems
Vehicle Speed SensorData Link Connectors; Analog Instrument Panels;
Cruise Control Systems; Electronic Suspension
Voltage RegulatorGenerators & Regulators
Water-In-Fuel SensorEngine Performance; Analog Instrument Panels
Wheel Speed SensorsAnti-Lock Brakes
Window Timer ModulePower Convertible Top
Windshield Intermittent Wiper RelayWiper/Washer Systems
Windshield Washer MotorWiper/Washer Systems
Wiper MotorWiper/Washer Systems

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