manual transmission FORD MUSTANG 2003 Repair Manual

Disassembly
Initial disassembly
1. Remove the differential housing cover (4033) and drain the lubricant into a suitable container.
2. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage.
3. Using the special tool, measure and note the differential ring gear backface runout. zRemove the special tool. Gauge, Differential Clutch
205-
135 (T80P-4946- A) Gauge, Differential Clutch
Torque
205-
013 (T59L-4204- A) Remover, Bearing
205-
055 (T71P-4621- B) Holding Fixture, Transmission
307-
003 (T57L- 500-B) Klj . 4 ba
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Component Tests
Brake Booster
1. Check the hydraulic brake system for leaks or insufficient fluid.
2. With the transmission (7003) in NEUTRAL, stop the engine (6007) and apply the parking brake control (2780). Apply the brake pedal several times to exhaust all vacuum in the system.
3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no
motion is felt, the power brake booster system is not functioning. Continue with the following
steps.
4. Remove the vacuum booster hose from the check valve connection. Manifold vacuum must be available at the check valve end of the vacuum booster hose with the engine at idle speed and
the transmission in NEUTRAL. If the manifold vacuum is available to the power brake booster,
connect the vacuum booster hose to the power brake booster check valve and repeat Steps 2
and 3.
5. If no downward movement of the brake pedal is felt, install a new power brake booster.
6. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10 minutes. Then apply the brake pedal with approximately 89 N (20 lb) of force. The
brake pedal feel should be the same as that noted with the engine operating. If the brake pedal
feels hard (no power assist), install a new power brake booster check valve and retest. If the
brake pedal feels spongy, bleed the hydraulic system to remove air. For additional information,
refer to Bleeding — System in this section. Check Valve z
Engine running at idle speed.
z CAUTION: Do not hold the brake pedal at 444 Nm
(100 lb) force for more than 5 seconds at a time.
z Apply brake pedal with approximately 444 Nm (100 lb)
force and hold.
z Check hydro-boost unit input seal, housing seal,
accumulator seal, piston seal and spool plug seal for
leakage.
z Is hydro- boost unit free of leaks? Yes
GO to
G6 .
No
INSTALL a new hydro- boost
unit. G6 CHECK RESERVE RETENTION
z
Engine running at idle speed.
z CAUTION: Do not hold the brake pedal at 444 Nm
(100 lb) force for more than 5 seconds at a time.
z Charge system to pressure by holding the steering wheel at
stop or by pressing the brake pedal with approximately 444
Nm (100 lb) force.
z Key in OFF position.
z Wait five seconds.
z Press brake pedal and observe if there is any power brake
reserve.
z Is there any power brake reserve? Yes
Hydro-
boost unit is OK.
No
INSTALL a new hydro- boost
unit. Klj . 13 ba
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Anti-Lock Brake Control Module Diagnostic Trouble Code (DTC) Index
DTC Description Source Action
B1318 Battery Voltage Low ABS/TC Go To Pinpoint Test C .
B1342 ECU Is Defective ABS/TC INSTALL a new anti-
lock brake control
module; REFER to Module . REPEAT the
self- test. B1484 Brake Pedal Input Open Circuit ABS/TC Go To Pinpoint Test D .
B1596 Repair Continuous Codes ABS/TC REPAIR the DTCs retrieved.
C1095 ABS Hydraulic Pump Motor Circuit
Failure ABS/TC Go To Pinpoint Test E .
C1145 RF Anti-
Lock Brake Sensor Input
Circuit Failure ABS/TC Go To Pinpoint Test F .
C1155 LF Anti-
Lock Brake Sensor Input
Circuit Failure ABS/TC Go To Pinpoint Test F .
C1165 RR Anti-
Lock Brake Sensor Input
Circuit Failure ABS/TC Go To Pinpoint Test F .
C1175 LR Anti-
Lock Brake Sensor Input
Circuit Failure ABS/TC Go To Pinpoint Test F .
C1222 Anti-
Lock Brake Sensor Mismatch ABS/TC Go To Pinpoint Test G .
C1233 LF Anti-
Lock Brake Sensor Input
Signal Missing ABS/TC Go To Pinpoint Test H .
C1234 RF Anti-
Lock Brake Sensor Input
Signal Missing ABS/TC Go To Pinpoint Test H .
C1235 RR Anti-
Lock Brake Sensor Input
Signal Missing ABS/TC Go To Pinpoint Test H .
C1236 LR Anti-
Lock Brake Sensor Input
Signal Missing ABS/TC Go To Pinpoint Test H .
C1266 ABS Valve Power Relay Circuit
Failure ABS/TC INSTALL a new anti-
lock brake control
module; REFER to Module . REPEAT the
self- test. C1805 Mismatched PCM and/or Anti-Lock
Brake Control Module ABS/TC CLEAR the DTCs. RETRIEVE the DTCs. If
DTC C1805 is retrieved, check the PCM
and Anti- Lock Brake Control Module is for
the correct vehicle. INSTALL a new PCM or
anti-lock brake control module as
necessary. CLEAR the DTCs. REPEAT the self-test. U1009 SCP (J1850) Invalid or Missing Data
for Engine Torque ABS/TC CARRY OUT the PCM self-
test. U1027 SCP (J1850) Invalid or Missing Data
for Engine RPM ABS/TC CARRY OUT the PCM self-
test. U1059 SCP (J1850) Invalid or Missing Data
for Transmission/Transaxle/PRNDL ABS/TC CARRY OUT the PCM self-
test. U1083 SCP (J1850) Invalid or Missing Data
for Engine Systems ABS/TC CARRY OUT the PCM self-
test. U1262 SCP (J1850) Communication Bus
Fault ABS/TC REFER to
Section 418 - 00 . Klj . 3 ba
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REMOVAL AND INSTALLATION
Switch —
Traction Control
Removal and Installation 1. NOTE: If the vehicle is equipped with an automatic transmission, position the shift lever in the 1
position before detaching the floor console finish panel.
Lifting from both sides, detach the floor console finish panel.
2. Disconnect the electrical connector and position the finish panel out of the way.
3. Reaching behind the center finish panel, push and detach the switch from the finish panel.
4. Disconnect the electrical connector and remove the switch.
SECTION 206-
09B: Anti-Lock Control — Traction Control 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 211-
00: Steering System — General Information 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants
Motorcraft MERCON® Multi-Purpose (ATF) Transmission Fluid XT-
2- QDX MERCON®
Power Steering Gear
Turning effort 2.27 Kg (5.0 lb)
Turns lock-to-
lock 2.38
Power Steering Purge Vacuum
Vacuum 68-
85 kPa (20- 25 in/hg) Power Steering Pump —
CII Flow 9.8 liters/minute
(2.6 gpm)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at 1,500 rpm Pressure 1,034 kPa
(150 psi)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at 1,500 rpm Minimum capacity 3.4 liters/minute
(0.9 gpm)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at idle
Pressure at 5,102 kPa (750
psi) Relief pressure 7,240-8,400 kPa
(1,050-1,230 psi) Power Steering Pump —
CIII Flow 9.8 liters/minute
(2.6 gpm)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at 1,500 rpm Pressure 1,034 kPa
(150 psi)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at 1,500 rpm Minimum capacity 4.7 liters/minute
(1.25 gpm)
Fluid @ 74°- 80° C (165°-175°
F)
Engine at idle
Pressure at 5,171 kPa (750 psi) Klj . 1 ba
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z
On some vehicles, the power steering pump high pressure port is inaccessible and the
special tool should then be installed either at the steering gear or at a point in the high
pressure line between the power steering pump and the steering gear.
2. Place a dial thermometer in the power steering pump reservoir.
3. Check the power steering fluid level. If necessary, add power steering fluid. zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
4. Install a digital tachometer.
5. 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.
Start the engine. Place the transmission in neutral. Set the parking brake. Raise the power
steering fluid temperature to 74- 80°C (165-175°F) by rotating the steering wheel fully to the left
and right several times.
6. Set the engine speed to 1500 rpm. Record the flow rate and pressure readings. zIf the flow rate is below the flow rate specification, a new power steering pump may need
to be installed. Continue with the test procedure.
z If the pressure reading is above the maximum pressure specification, then check power
steering hoses for kinks and restrictions.
7. Partially close the gate valve to obtain 750 psi. Set the engine speed at idle. Record the flow rate.
zIf the flow is less than the specified flow rate, then install a new power steering pump. For
additional information, refer to Section 211 - 02 .
8. CAUTION: Do not allow the gate valve to remain closed for more than 5 seconds.
Completely close and partially open the gate valve 3 times. Record the pressure relief valve
actuation pressure reading. zIf the pressure does not meet the relief pressure specification, install a new power
steering pump. For additional information, refer to Section 211 - 02 .
9. Set engine speed to 1500 rpm. Record the flow rate. zIf the flow rate varies more than 3.785 liters/minute (1 gallon/minute) from the initial flow
rate reading, install a new power steering pump. For additional information, refer to
Section 211 - 02 .
10. 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.
Set the engine speed at idle. Turn (or have an assistant turn) the steering wheel to the left and
right stops. Record flow rate and pressure readings at the stops.
zThe pressure reading at both stops should be nearly the same as the maximum pump
relief pressure.
z The flow rate should drop below 1.9 liters/minute (0.5 gallons/minute).
z If the pressure does not reach the maximum pump relief pressure or the flow rate does
not drop below the specified value, excessive internal leakage is occurring. Install a new
steering gear as necessary. For additional information, refer to Section 211 - 02 . Klj . 9 ba
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11. Turn (or have an assistant turn) the steering wheel slightly in both directions and release quickly
while watching the pressure gauge.
zThe pressure reading should move from the normal back pressure reading and snap
back as the steering wheel is released.
z If the pressure returns slowly or sticks, the rotary valve in the steering gear is sticking or
the steering column is binding. Check the steering column and linkages before servicing
the steering gear.
Tie- Rod Articulation Torque
1. NOTE: This check may be done with the steering gear on or off the vehicle.
Disconnect the tie- rod end from the front wheel spindle. For additional information, refer to
Section 211 - 02 .
2. Move the front wheel spindle tie- rod back and forth three times.
3. Hook the special tool 211- 034 (T74P-3504-Y) over the tie-rod end or the threaded portion of the
front wheel spindle tie- rod and measure the force required to move the front wheel spindle tie-
rod. Refer to Tie- Rod Articulation Torque in General Specifications in this section.
4. If the force required to move the front wheel spindle tie- rod does not meet the specifications,
install a new front wheel spindle tie- rod. For additional information, refer to Section 211 - 02 .
Steering Gear Valve 1. With the vehicle in motion, place the transmission in NEUTRAL and turn the engine OFF. zIf the vehicle does not pull with the engine OFF, install a new steering gear. For
additional information, refer to Section 211 - 02 .
2. If the vehicle pulls with the engine OFF, cross- switch the front wheels.
3. If the vehicle pulls to the opposite side, cross- switch the front and rear wheels on the same side.
4. If the vehicle pull direction does not change, check the front suspension components, wheel alignment and frame alignment. For additional information, refer to Section 204 - 00 or frame
dimensions manual. Klj . 10 ba
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SPECIFICATIONS
a
Once torque is reached, continue turning to align slot in nut with cotter pin hole in tie- rod.
SECTION 211-
02: Power Steering 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants
Motorcraft Multi-Purpose (ATF) Transmission Fluid XT
-2-QDX MERCON®
Silicone Dielectric Compound D7AZ-
19A331-A ESE-
M1C171- A Steering Gear Grease C3AZ-19578-
A ESW-
M1C87- A
Torque Specifications Description Nm lb-
ft lb-
in Front wheel spindle tie-
rod 100 74 —
Power steering pump mounting bolts (CII pump) 51 38 —
Power steering pump mounting bolts
(CIII pump) 25 18 —
Pressure line fitting
(CII pump) 40 30 —
Pressure line fitting
(CIII pump) 65 48 —
Pressure line fitting 30 22 —
Return line fitting
(steering gear) 30 22 —
Steering gear mounting nut 48 35 —
Steering intermediate shaft coupling pinch bolt 34 25 —
Tie-
rod end castellated nut 56
a 11
a —
Tie-
rod end jam nut 55 41 — Klj . 1 ba
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6. Remove the pinch bolt and disconnect the coupling from the steering column.
7. Disconnect the electrical connector.
Vehicles with manual transmission 8. Remove the nuts and the steering column. zDiscard the nuts.
Vehicles with automatic transmission 9. Remove the nuts and lower the steering column. zDiscard the nuts. Klj . 2 ba
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DESCRIPTION AND OPERATION
Steering Column Switches
The steering column switches system consists of the following components:
zmultifunction switch (13K359)
z key release button (manual transmission only) (3F527)
z ignition switch (11572)
The integrated multifunction switch is mounted to the LH side of the steering column and controls the
turn signals, hazard flasher, windshield wiper/washer control, and headlamp dimmer/flash- to-pass.
The key release button is equipped with manual transmissions only.
The ignition switch is mounted below the steering column and is activated by rotating the key lock
cylinder on the steering column. SECTION 211-
05: Steering Column Switches 2003 Mustang Workshop Manual Klj . 1 ba
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