automatic transmission FORD MUSTANG 2003 Repair Manual

DIAGNOSIS AND TESTING
Special Testing Procedures
The special tests are designed to aid the technician in diagnosing the hydraulic and mechanical portion
of the transmission.
Engine Idle Speed Check
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the
engine idle speed.
Line Pressure Test
CAUTION: Carry out the line pressure test prior to carrying out the stall speed test. If the
line pressure is low at stall, do not carry out stall speed test or further transmission damage
will occur. Do not maintain WOT in any transmission range for more than five seconds.
This test verifies that the line pressure is within specification.
1. Connect pressure gauge to line pressure tap.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Item Part Number Description
1 — Direct clutch pressure tap
2 — Forward clutch pressure tap
3 — Electronic pressure control (EPC) pressure tap
4 — Intermediate clutch pressure tap
5 — Line pressure tap Klj . 1 ba
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DIAGNOSIS AND TESTING
Leakage Inspection
CAUTION: Do not try to stop the fluid leak by increasing the torque beyond specifications.
This may cause damage to the case threads.
Check the fluid filler tube connection at the transmission case. If leakage is found here, install a new
grommet.
Check the VSS plug or VSS sensor O-ring (model dependent). If leakage is found install a new O- ring.
Check fluid lines and fittings between the transmission and the cooler in the radiator tank for
looseness, wear, or damage. If leakage cannot be stopped by tightening a fluid tube nut, install new
parts. When fluid is found leaking between the case and cooler line fitting, check for missing or
damaged O- ring, then tighten the fitting to maximum specification.
If the leak continues, install a new cooler line fitting and tighten to specification. The same procedure
should be followed for fluid leaks between the radiator cooler and the cooler line fittings in this section;
refer to Section 307 - 02 .
Check the engine coolant in the radiator. If transmission fluid is present in the coolant, the cooler in the
radiator is probably leaking.
The cooler can be further checked for leaks by disconnecting the lines for the cooler fittings and
applying no more than 345 kPa (50 psi) air pressure to the fittings. Remove the radiator cap to relieve
the pressure buildup at the exterior of the oil cooler tank. If the cooler is leaking and or will not hold
pressure, install a new cooler.
If leakage is found at the transmission range selector lever, install a new seal.
If leakage is found at the transmission internal harness connector, install a new O- ring. 4R70W External Sealing SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 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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Main Controls
·
No. 6 shuttle ball, manual
valve, main regulator valve, low
servo modulator valve stuck,
damaged or assembled
incorrectly ·
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. Low Reverse Servo
·
Seals (piston and cover)
damaged ·
Inspect for damage. Repair as required. ·
Servo cover retaining ring assembled incorrectly. ·
Anchor pins (case) damaged.
Shift Concerns: No Manual 2nd Gear Possible Component Reference/Action
217 —
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. 317 —
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. Main Controls
·
3- 4 shift valve, 1- 2 and 2-3
shift valve, 3- 4 capacity
modulator valve stuck,
damaged or assembled
incorrectly ·
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.
Shift Concerns: 1-2 Shift (Automatic) Possible Component Reference/Action
220 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, ·
Carry out Self- Test. Refer to the Powertrain Control/Emissions Klj . 16 ba
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piston
·
Springs damaged or
broken ·
Inspect for damage. Repair as required. ·
Case bore scored ·
Inspect for damage. Repair as required.
Shift Concerns: 2-3 Shift (Automatic) Possible Component Reference/Action
221 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, shift solenoids, 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 A or
Go To Pinpoint Test E . Repair as required. Clear DTCs, road test
and repeat Self- Test. ·
Engine driveability concerns ·
Refer to Routine 253. 321 —
HYDRAULIC/MECHANICAL ROUTINE 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
·
Direct clutch pressure ·
Check pressure at direct clutch tap; refer to Line Pressure
Chart for specifications. If not OK, check the main controls. Main Controls
·
2- 3 shift valve, check ball No.
9 or No. 3, solenoid pressure
regulator valve, damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Shift solenoid SSB
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. ·
Output shaft seals damaged
or cup plug leaking or missing ·
Inspect for damage and repair as required. ·
2- 3 accumulator damaged or
stuck ·
Inspect piston seal and bore for damage. Repair as required. ·
Solenoid screen (in main
control) blocked or damaged ·
Clean or install a new screen. Intermediate One-
Way Clutch
Assembly ·
Not overrunning or damaged ·
Inspect for damage. Repair as required. Output Shaft
·
Seal rings damaged ·
Inspect for damage. Repair as required. ·
Cup plug damaged or missing Klj . 18 ba
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Direct Clutch Assembly
·
Seals or piston damaged ·
Inspect for damage. Repair as required. ·
Friction elements worn or
damaged ·
Inspect for damage. Repair as required. ·
Check ball not seating ·
Inspect for damage. Repair as required. ·
Return spring assembly
damaged ·
Inspect for damage. Repair as required. Case
·
Output shaft rear seals
leaking or damaged ·
Inspect for damage. Repair as required. Inspect case for
damaged seal area. If damaged, install a new case. 2-
3 Accumulator ·
Damaged accumulator piston ·
Inspect for damage. Repair as required. ·
Springs damaged or broken ·
Inspect for damage. Repair as required. ·
Case bore scored ·
Inspect for damage. Repair as required.
Shift Concerns: 3-4 Shift (Automatic) Possible Component Reference/Action
222 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, shift
solenoids, OSS, transmission
control switch (TCS) ·
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 E . Repair
as required. Clear DTCs, road test and repeat Self- Test. ·
Engine driveability concerns ·
Refer to Routine 253. 322 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, 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
·
Forward clutch pressure, direct
clutch pressure, line pressure ·
Check line, direct and forward clutch pressures at
appropriate taps; refer to Line Pressure Chart for
specifications. If pressures are out of specification, check
main controls. Main Controls
·
3- 4 shift valve, solenoid pressure
regulator valve, OD servo regulator,
3- 4 capacity modulator valve, 1- 2
and 2- 3 shift valves stuck, damaged
or assembled incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to specifications ·
Tighten bolts to specifications. ·
SSA or SSB 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 Klj . 19 ba
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required.
·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
OD servo rod and piston cushion
spring or seals damaged ·
Inspect for damage. Repair as required. ·
Worn or damaged OD servo anchor
pins ·
Inspect for damage. Repair as required. ·
No. 2, No. 4, No. 7 and No. 9 check
balls damaged or missing ·
Inspect for damage. Repair as required. ·
Solenoid screen blocked or
damaged ·
Clean or install a new screen. Pump
·
Porosity/cross leaks, balls missing,
damaged or leaking ·
Inspect for porosity/leaks, balls missing. Install a new
pump as required. ·
Gaskets damaged ·
Inspect for damage. Install new gaskets as required. OD Band
·
OD band and reverse clutch drum
assembly damaged, worn or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
Intermediate one- way clutch
assembly damaged ·
Inspect for damage. Repair as required. Forward Clutch Assembly
·
Seals or piston damaged ·
Inspect for damage. Repair as required. ·
Friction elements worn or damaged ·
Inspect for damage. Repair as required. ·
Check ball stuck, damaged or not
seating correctly ·
Inspect for damage. Repair as required. Input Shaft
·
Seals damaged ·
Inspect for damage. Repair as required.
Shift Concerns: 4-3 Shift (Automatic) Possible Component Reference/Action
223 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle wiring
harnesses, PCM, shift solenoids,
transmission control switch (TCS) ·
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 . Repair as required.
Clear DTCs, road test and repeat Self- Test. 323 —
HYDRAULIC/MECHANICAL ROUTINE Incorrect Pressures
·
Forward clutch pressure, line pressure ·
Check line and forward clutch at pressure taps; refer to
Line Pressure Chart for specifications. If out of
specification, check the main controls. Main Controls
·
3- 4 shift valve, solenoid pressure
regulator valve, OD servo regulator, 3-
4 capacity modulator, 1- 2 and 2-3 shift
valves stuck, damaged or assembled ·
Inspect for damage. Repair as required. Klj . 20 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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GENERAL PROCEDURES
Transmission Fluid Drain and Refill
Draining
CAUTION: Always refer to the instructions supplied with the flush and fill machine.
NOTE: Draining fluid from the transmission by removing only the fluid pan is acceptable for vehicles
that do not have a torque converter drain plug, for normal or severe duty fluid maintenance.
NOTE: A new procedure for draining and adding transmission fluid using a suitable transmission flush
and fill machine has been added. The following procedure has different methods for draining and
refilling the listed vehicles:
zAll vehicles using a suitable flush and fill machine.
z Vehicles equipped with a torque converter drain plug.
z Vehicles without a torque converter drain plug.
Use the method that is applicable to your vehicle.
All vehicles using a suitable flush and fill machine 1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100 - 02 .
2. Use a suitable flush and fill machine to change the fluid.
3. When connecting the flush and fill machine, connect the machine to the fluid cooler tube after the fluid cooler on the cooler return line. This will help remove any foreign material trapped in
the fluid coolers. Refill SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Special Tool(s)
Automatic Transmission Flush
and Fill Machine
211-
00018
Automatic Transmission Flush
and Fill Machine
199- 00010 or equivalent
Material Item Specification
MERCON® V Automatic
Transmission Fluid
XT
-5-QM MERCON®
V Klj . 1 ba
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