power steering FORD MUSTANG 2003 Repair Manual

6. Rotate the steering column intermediate shaft as necessary to access the pinch bolt. Remove
and discard the pinch bolt.
7. Lower the vehicle.
8. Turn the steering wheel back to the straight- ahead position. Turn the ignition key to the locked
position.
9. CAUTION: Do not rotate the steering wheel when the lower steering column shaft is
disconnected, or damage to the air bag sliding contact will result.
Disconnect the steering column intermediate shaft coupling (3A525).
10. Remove the nuts, washers and bolts. Position the steering gear (3504) forward.
11. Disconnect the power steering hoses. Remove and discard the seal rings. zPlug or cap the power steering hoses and steering gear ports to prevent damage and the
entry of foreign material. Klj . 2 ba
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2. Fill and leak check the power steering system. For additional information, refer to
Section 211 -
00 . Klj . 4 ba
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DISASSEMBLY AND ASSEMBLY
Gear
Disassembly
NOTE:
The steering gear is serviceable as either a long or short rack assembly. This procedure covers
the removal and installation of the components not supplied with a short rack assembly. On short rack
assembly only the front wheel spindle tie- rods and front suspension steering ball stud dust seals are
serviced separately.
All steering gears
1. Remove the steering gear mounting bracket housing insulators. zDiscard worn or damaged steering gear mounting bracket housing insulators.
SECTION 211-
02: Power Steering 2003 Mustang Workshop Manual Special Tool(s)
Head Mounting Fixture
303-
D041 (D83L-500- B1) or
Equivalent Inner Tie Rod Socket Tool
211-
D025 (D90P-3290- A) or
Equivalent Steering Gear Holding Fixture
211-
D011 (D87P-3504- B) or
Equivalent
Material Item Specification
Multi-
Purpose Grease
XG- 4 ESR-
M1C159-
A Silicone Brake Caliper Grease
and Dielectric Compound
D7AZ-
19A331- A ESE-
M1C171-
A Klj . 1 ba
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2. Install the steering gear into the special tools.
3. Clean the exterior of the steering gear with solvent. If necessary, drain any excess power
steering fluid.
4. Inspect the steering gear housing for cracks and other damage. If necessary, install a new steering gear.
5. Verify the power steering gear input shaft bearing rotates freely. If necessary, install a new steering gear.
6. Place an alignment mark on the tie- rod ends, nuts and front wheel spindle tie- rods. Remove the
tie- rod ends and nuts.
7. CAUTION: Use care not to damage the front suspension steering ball stud dust
seals. If the front suspension steering ball stud dust seals are damaged, this will allow
contamination into the steering gear and cause leakage.
Remove the clamps and the two front suspension steering ball stud dust seals.
zDiscard any clamps that are damaged or excessively corroded.
z Discard any front suspension steering ball stud dust seals that are damaged. Klj . 2 ba
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GENERAL PROCEDURES
Supplemental Restraint System (SRS) Deactivation and
Reactivation
Deactivation
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint
system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury
in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium
hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your
hands with soap and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air
bag deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be installed
new, not repainted.
WARNING: The restraint system diagnostic tool is for restraint system service only.
Remove from vehicle prior to road use. Failure to remove could result in injury and possible
violation of vehicle safety standards.
1. WARNING: To avoid accidental deployment and possible personal injury, the
backup power supply must be depleted before repairing or replacing any front or side air
bag supplemental restraint system (SRS) components and before servicing, replacing,
adjusting or striking components near the front or side air bag sensors, such as doors,
instrument panel, console, door latches, strikers, seats and hood latches.
Please refer to the appropriate vehicle shop manual to determine location of the front air
bag sensors.
The side air bag sensors are located at or near the base of the B- pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and
wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). SECTION 211-
04: Steering Column 2003 Mustang Workshop Manual Special Tool(s)
Diagnostic Tool, Restraint
System (2 Req'd)
418-
F088 (105- R0012) Klj . 1 ba
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REMOVAL AND INSTALLATION
Ignition Switch Lock Cylinder —
Non-Functional
Removal and Installation 1. NOTE: Make sure the front wheels are in the straight- ahead position.
Disconnect the battery ground cable (14301) and wait at least one minute to allow the depletion
of the restraint system backup power supply. For additional information, refer to Section 414 -
01 .
2. WARNING: To avoid the risk of serious personal injury, read and follow all
warnings, cautions, notes and instructions in the deactivation procedure.
Deactivate the supplemental restraint system (SRS). For additional information, refer to
Supplemental Restraint System (SRS) Deactivation and Reactivation in this section.
3. WARNING: To reduce the risk of serious personal injury, read and follow all
warnings, cautions, notes and instructions in the steering wheel removal and installation
procedure.
Remove the steering wheel assembly. For additional information, refer to Wheel in this section.
4. Twist off the cap from the ignition switch cylinder.
5. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a
new lock cylinder using the appropriate lock repair package (F85Z-11582- AA). The lock repair
package includes a detailed instruction sheet to build the new lock cylinder to the current key
code of the vehicle.
SECTION 211-
04: Steering Column 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Wheel
Removal and Installation
1. Disconnect the battery ground cable (14301) and wait at least one minute to allow the depletion of the restraint system backup power supply. For additional information, refer to Section 414 -
01 .
2. Turn the steering wheel to the straight- ahead position and the ignition switch to the OFF
position.
3. WARNING: To avoid the risk of serious personal injury, follow all warnings,
cautions, notes and instructions in the beginning of the deactivation procedure.
Deactivate the supplemental restraint system (SRS). For additional information, refer to
Supplemental Restraint System (SRS) Deactivation and Reactivation in this section.
4. WARNING: To avoid risk of serious personal injury, follow all warnings, cautions,
notes and instructions in the driver air bag removal and installation procedure.
Remove the driver air bag module. For additional information, refer to Section 501 - 20B .
5. Remove and discard the steering wheel retaining bolt.
6. CAUTION: Removing the steering wheel without using a puller can damage the
column bearings.
Use a suitable puller to remove the steering wheel (3600).
SECTION 211-
04: Steering Column 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Column
Removal and Installation
All vehicles
1. Disconnect the battery ground cable and wait at least one minute to allow the depletion of the restraint system backup power supply. For additional information, refer to Section 414 - 01 .
2. WARNING: To avoid the risk of serious personal injury, follow all warnings,
cautions, notes and instructions at the beginning of the deactivation procedure.
Deactivate the supplemental restraint system (SRS). For additional information, refer to
Supplemental Restraint System (SRS) Deactivation and Reactivation in this section.
3. WARNING: To reduce the risk of serious personal injury, follow all warnings,
cautions, notes and instructions in the clockspring removal and installation procedure.
Remove the clockspring (14A664). For additional information, refer to Section 501 - 20B .
4. Remove the multi- function switch (13K359).
1. Remove the screws.
2. Disconnect the electrical connector.
3. Remove the multi- function switch.
5. Disconnect the ignition switch electrical connector. 1. Remove the bolt.
2. Disconnect the electrical connector.
SECTION 211-
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DIAGNOSIS AND TESTING
Steering Column Switches
Refer to Wiring Diagrams Cell
13 , Power Distribution for schematic and connector information.
Refer to Wiring Diagrams Cell 81 , Interval Wiper/Washer for schematic and connector information.
Refer to Wiring Diagrams Cell 85 , Headlamps for schematic and connector information.
Refer to Wiring Diagrams Cell 90 , Turn/Stop/Hazard Lamps for schematic and connector information.
Inspection and Verification 1. Verify the customer concern by operating the multifunction or ignition switch.
2. Visually inspect for obvious signs of mechanical and electrical damage.
3. If the concern remains after the inspection, connect the scan tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan
tool menu. If the scan tool does not communicate with the vehicle:
zcheck that the program card is correctly installed.
SECTION 211-
05: Steering Column Switches 2003 Mustang Workshop Manual Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent scan
tool 73 Digital Multimeter
105-
R0051 or equivalent
Visual Inspection Chart Mechanical Electrical
z
Ignition key
z Ignition switch
z Multifunction switch
z Turn signal switch
z Hazard/flasher switch z
Battery junction box (BJB) Fuses:
„(3) IGN (40A)
z Central junction box (CJB) Fuses:
„6 (25A)
„ 39 (5A)
z Damaged wiring harness
z Loose or corroded connections Klj . 1 ba
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a
20- 200 seconds to leakdown 3.18 mm (0.125 in) with 225 Newtons (50 pounds) load and tappet filled
with leak- down fluid. —
desired Connecting rod bearing-
to-crankshaft clearance
— allowable 0.022-
0.069 mm (0.00086- 0.0027 in) Connecting rod side clearance 0.11-
0.49 mm (0.0047- 0.0193 in) Balance Shaft
Journal diameter 52.108-
52.082 mm (2.0515- 2.0505 in) Bore inside diameter 55.689-
55.664 mm (2.192- 2.191 in) Maximum runout 0.025 mm (0.001 in)
End play 0.075-
0.200 mm (0.003- 0.008 in)
Torque Specifications Description Nm lb-
ft lb-
in EGR transducer bracket-
to-intake manifold bolts 10 — 89
Ignition coil-
to-intake manifold bolts 6 — 53
Water outlet tube-
to-intake manifold stud bolt 10 — 89
EGR tube-
to-EGR valve nut 40 30 —
Water outlet tube-
to-front water pump bolt 10 — 89
Fuel supply manifold bolts 10 — 89
LH valve cover-
to-cylinder head bolts 10 — 89
LH valve cover-
to-cylinder head stud bolts 10 — 89
EGR tube-
to-exhaust manifold nut 40 30 —
RH valve cover-
to-cylinder head bolts 10 — 89
RH valve cover-
to-cylinder head stud bolts 10 — 89
Coolant recovery reservoir-
to-cylinder head stud bolts 10 — 89
Coolant recovery reservoir-
to-bracket bolts 5 — 44
Crankshaft pulley bolt 160 118 —
Camshaft position sensor bolts 3 — 27
Camshaft synchronizer-
to-front cover bolt 25 18 —
Front cover-
to-cylinder block bolts 25 18 —
Radiator fan shroud-
to-radiator bolts 9 — 80
Camshaft thrust plate-
to-cylinder block bolts 12 9 —
Camshaft synchronizer drive gear-
to-camshaft bolt 45 33 —
Timing chain tensioner-
to-cylinder block bolts 12 9 —
Exhaust manifold-
to-cylinder head nuts 33 24 —
Power steering pump bracket-
to-water pump nuts 20 15 —
Power steering pump bracket-
to-generator bracket bolts 20 15 —
Generator bracket-
to-cylinder head bolts 40 30 —
Exhaust manifold studs 8 — 71
A/C compressor bracket-
to-cylinder head bolts 48 35 —
A/C compressor bracket-
to-cylinder head nut 48 35 — Klj . 4 ba
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