transmission fluid FORD MUSTANG 2003 Repair Manual

Item Part Number Description
1 7902 Torque converter
2 7A248 Front pump seal
3 7A248 Front pump seal
4 N605789-S101 Bolt
5 7A106 Front pump body assembly
6 7A136 Pump gasket
7 390318-
S2 Pipe plug —
1/8 —27 Dryseal tapered 8 7005 Case
9 7034 Vent
10 N811757-S100 Speed sensor seal
11 7H103 Output shaft speed (OSS) sensor
12 7B498 Manual control lever seal assembly
13 7086 Extension housing gasket
14 7A039 Extension housing
15 N803737-S1101 Bolt —
M8-1.25 x 30 15 N606047-S101 Bolt —
M8-1.25 x 70 15 N803521-S1101 Bolt —
M8-1.25 x 1.25 x 0.54 15 N811524-S101 Bolt —
M8-1.25 x 42 16 7052 Oil seal
17 7Z276 Seal —
bulkhead assembly 18 7G276 Bulkhead assembly wiring connector
19 7G276 Molded lead frame
20 7A194 Transmission fluid pan
21 7A191 Gasket Klj . 2 ba
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Fluid Leakage in Torque Converter Area
In diagnosing and correcting fluid leaks in the front pump support and gear and torque converter area,
use the following procedures to locate the exact cause of the leakage. Leakage at the front of
transmission, as evidenced by fluid around the torque converter housing, may have several sources.
By careful observation it is possible, in many instances, to pinpoint the source of leak before removing
the transmission from the vehicle. The paths which the fluid takes to reach the bottom of the torque
converter housing are shown in the illustration. The five steps following correspond with the numbers
in the illustration.
1. Fluid leaking by the front pump seal lip will tend to move along the impeller hub and onto the back of the impeller housing. Except in the case of a total seal failure, fluid leakage by the lip of
the seal will be deposited on the inside of the torque converter housing only, near the outside
diameter of the housing.
2. Fluid leakage by the outside diameter of the front pump seal and front pump body will follow the same path that leaks by the inside diameter of the front pump seal follow.
3. Fluid that leaks by a front pump to case bolt or pump gasket will be deposited on the inside of the torque converter housing only. Fluid will not be deposited on the back of the torque
converter.
4. Fluid leakage from the converter drain plug, (model dependent) converter seal weld or converter to flexplate stud weld will appear at the outside diameter of the torque converter on the back
face of the flexplate and in the converter housing only near the flexplate. Fluid leaks from the
torque converter will leave a ring of fluid around the inside of the torque converter housing.
5. NOTE: White facial tissue paper may aid in determining the color (red is transmission fluid) and
source of the leaking fluid.
Engine oil leaks are sometimes incorrectly diagnosed as transmission pump gasket leaks. The 22 7D273 Fluid tube connector
23 87650-S2 Converter drain plug Klj . 3 ba
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following areas of possible leakage should also be checked to determine if engine oil leakage is
causing the concern.
a. Leakage at the engine valve cover gasket may allow oil to flow over the torque converter housing or seep down between the torque converter housing and cylinder block causing oil to
be present in or at the bottom of the torque converter housing.
b. Oil galley plug leaks will allow oil to flow down the rear face of the cylinder block to the bottom of the torque converter housing.
c. Leakage at the crankshaft rear oil seal will work back to the flexplate, and then into the torque converter housing.
d. Leakage at engine oil pressure sensor.
Leak Check Test 1. Remove the fluid level indicator and note the color of the fluid. Original factory fill fluid is dyed red to aid in determining if leakage is from the engine or transmission. Unless a considerable
amount of makeup fluid has been added or the fluid has been changed, the red color should
assist in pinpointing the leak.
2. Remove the torque converter housing cover. Clean off any fluid from the top and bottom of the torque converter housing, front of the case and rear face of the engine and oil pan. Clean the
torque converter area by washing with a suitable nonflammable solvent and blow dry with
compressed air.
3. Wash out the torque converter housing, the front of the flexplate and the converter drain plugs. The torque converter housing may be washed out using cleaning solvent and a squirt- type oil
can. Blow all washed areas dry with compressed air.
4. Start and run the engine until the transmission reaches its normal operating temperature. Observe the back of the cylinder block and top of the torque converter housing for evidence of
fluid leakage. Raise the vehicle on a hoist; refer to Section 100 - 02 and run the engine at fast
idle, then at engine idle, occasionally shifting to the Overdrive and Reverse ranges to increase
pressure within the transmission. Observe the front of the flexplate, back of the cylinder block
(in as far as possible), and inside the torque converter housing and front of the case. Run the
engine until fluid leakage is evident and the probable source of leakage can be determined.
Leak Check Test With Black Light Used With 12 Volt Master UV Diagnostic Inspection Kit
Oil soluble aniline or fluorescent dyes premixed at the rate of 2.5ml (1/2 teaspoon) of dye powder to
0.235L (1/2 pint) of transmission fluid have proved helpful in locating the source of fluid leakage. Such
dyes may be used to determine whether an engine oil or transmission fluid leak is present, or if the
fluid in the fluid cooler leaks into the engine cooling system. A black light must be used with the
fluorescent dye solution. Klj . 4 ba
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DIAGNOSIS AND TESTING
Transmission Fluid Cooler
CAUTION: Whenever a transmission has been disassembled to install new parts, the
cooler bypass valve (CBV), all transmission fluid coolers (in tank and auxiliary) and
transmission fluid cooler lines must be cleaned and backflushed. Use a suitable the torque
converter/fluid cooler cleaner.
NOTE: Cleaning and backflushing the transmission fluid cooling system along with following all the
normal cleaning and inspection procedures in this section during disassembly and reassembly will
keep contamination from reentering the transmission and causing a repeat repair.
When internal wear or damage has occurred in the transmission, metal particles, clutch plate material,
or band material may have been carried into the torque converter and transmission fluid cooler. These
contaminants are a major cause of recurring transmission troubles and must be removed from the
system before the transmission is put back into use.
Transmission Fluid Cooler Flow Test
NOTE: The transmission linkage/cable adjustment, fluid level and line pressure must be within
specification before carrying out this test. Refer to Section 307 - 05 for adjustments.
1. Remove fluid level indicator from fluid filler tube.
2. Place funnel in fluid filler tube.
3. Position the vehicle on a hoist. For additional information, refer to Section 100 - 02 .
4. Remove the cooler return line (top fitting) from the fitting on the transmission case.
5. Connect one end of a hose to the cooler return line and route other end of the hose up to a point where it can be inserted into the funnel at the fluid filler tube.
6. Remove the safety stands and lower the vehicle. Insert end of hose into the funnel.
7. Start the engine and run it at idle with the transmission in NEUTRAL.
8. When fluid flows from the hose in a steady stream, a liberal amount of fluid should be observed. "Liberal" is about 1 liter (1 quart) delivered in 15 seconds. If a liberal flow is observed, the test is
complete.
9. If the flow is not liberal, stop the engine. Disconnect the hose from the cooler return line and connect it to the converter outlet fitting (bottom fitting) on the transmission case.
10. Repeat steps 6 and 7. If flow is now approximately 1 liter (1 quart) in 15 seconds, refer to Transmission Fluid Cooler — Backflushing and Cleaning in this section. If the flow is still not
approximately 1 liter (1 quart) in 15 seconds, repair or install pump and or converter.
For the installation of new transmission fluid cooler or tubes, refer to Section 307 - 02 .
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Diagnosis By Symptom
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Transmission Fluid Pressure
Gauge
307-
004 (T57L-77820- A) Air Test Plate, Transmission
307-
246 (T92P-7006- A) Breakout Box, EEC-V Control
System
418- 049 (T94L-50- EEC-V) or
equivalent MLP-
TR Cable
418- F107 (007- 00111) or
equivalent Worldwide Diagnostic System
(WDS)
418-
F224
New Generation STAR (NGS)
Tester
418- F052 or equivalent scan
tool Transmission Tester
307-
F016 (007- 00130) or
equivalent Trans Tester TR/MLP Overlay
and Manual
007-
00131 or equivalent 73 III Automotive Meter Klj . 1 ba
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Condition.
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 the digital
transmission range (TR) sensor is correctly adjusted. Adjust the
digital TR sensor as necessary. Incorrect Pressures
·
Low forward clutch
pressure, low line
pressure ·
Check pressure at line and forward clutch tap. Refer to Line Pressure
Chart for specification. If pressures are low, check the following
components: oil filter and seal assembly, main controls, pump
assembly, forward clutch 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, manual
valve — stuck,
damaged ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Gaskets damaged ·
Inspect gaskets for damage and install a new gasket. ·
2- 3 accumulator and
seals damaged ·
Inspect piston, seals and bore for damage. Repair as required. ·
Pressure regulator
valve ·
Inspect the diameter for wear. Pump Assembly
·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Porosity/cross
leaks/ball missing or
leaking, plugged hole ·
Inspect for porosity and leaks. Repair as required. ·
No. 3 and No. 4 seal
rings damaged ·
Inspect seals for damage. Repair as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Forward Clutch
Assembly
·
Seals, piston damaged ·
Inspect seals for damage. Repair as required. ·
Check balls damaged,
missing, mislocated,
not seating correctly ·
Inspect for mislocation, poor seating, damage. Install a new cylinder
as required. ·
Friction elements
damaged or worn ·
Check for abnormal wear, damage. Repair as required. One-
Way Clutch
Assembly (Planetary) ·
Worn, damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. Output Shaft Klj . 4 ba
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·
Damaged ·
Inspect for damage. Install new components as required.
Engagement Concern: No Reverse Possible Component Reference/Action
202 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 302 —
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 reverse clutch
pressure, low reverse band
pressure, low line pressure ·
Check pressure at line pressure tap; refer to Line Pressure Chart
for specifications. If pressures are low, check the following
components: oil filter and seal assembly, main controls, reverse
servo, pump assembly, reverse clutch assembly. Fluid Filter and Seal
Assembly
·
Plugged, damaged ·
Install a new filter and seal assembly. Main Controls
·
No. 6 shuttle ball, manual
valve, main regulator valve,
1- 2 accumulator seals
stuck or damaged ·
Inspect for damage. Repair as required. ·
Loose bolts ·
Tighten bolts to specifications. ·
Gasket damaged ·
Inspect for damage and install a new gasket. Low/Reverse Servo
·
Seals (piston and cover)
damaged ·
Inspect for damage. Repair as required. ·
Servo cover retaining ring
damaged ·
Anchor pins (case)
damaged Pump Assembly
·
Loose bolts ·
Tighten bolts to specifications. ·
Porosity/cross leaks/ball
missing or leaking, plugged
hole ·
Inspect pump assembly. Install new as required. ·
Gasket damaged ·
Inspect for damage and install a new gasket. ·
No. 1 and 2 seal rings
damaged ·
Inspect for damage. Repair as required. Reverse Clutch Assembly Klj . 5 ba
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·
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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the engine mounts
Incorrect Pressures
·
High forward clutch
pressure, high line
pressure, high EPC
pressure ·
Check pressure at line, EPC and forward pressure taps. Refer to
Line Pressure Chart for specifications. If pressures are high, check
the following possible components: main controls, pump assembly. Main Controls
·
Main regulator valve
stuck, damaged ·
Inspect and repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
EPC solenoid stuck or
damaged ·
Inspect for damage or contamination. Carry out EPC test in Routine
204. Repair as required. Case
·
2- 3 accumulator
seal/retainer stuck,
damaged ·
Inspect for damage. Repair as required. Pump Assembly
·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Porosity/cross leaks ·
Inspect for porosity/leaks. Install a new pump as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Forward Clutch Assembly
·
Check balls missing or
damaged ·
Inspect for mislocation, poor seating, damage. Install a new forward
clutch cylinder. ·
Friction element
damaged or worn ·
Inspect for damage. Repair as required. ·
Forward clutch wave
spring damaged ·
Inspect for damage. Repair as required. ·
Forward clutch return
spring damaged ·
Inspect for damage. Repair as required.
Engagement Concern: Delayed/Soft Reverse Possible Component Reference/Action
205 —
ELECTRICAL
ROUTINE ·
No Electrical Concerns 305 —
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 Klj . 8 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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