engine FORD MUSTANG 2003 Workshop Manual

a
Carry out electrical routine first.
Diagnostic Routines Engagement Concerns
No Forward 201 301
No REVERSE 202 302
Harsh REVERSE 203 303
Harsh Forward 204 304
Delayed/Soft Reverse 205 305
Delayed/Soft Forward 206 306
Shift Concerns
Some/All Shifts Missing 210 310
Timing Concerns
—
Early/Late 211 311
—Erratic/Hunting 212 312
Feel
—
Soft/Slipping 213 313
—
Harsh 214 314
No 1st Gear, Engages in Higher Gear 215 315
No Manual 1st Gear 216 316
No Manual 2nd Gear 217 317
Torque Converter Operation Concerns
No Apply 240 340
Always Applied/Stalls Vehicle 241 341
Cycling/Shudder/Chatter 242 342
Other Concerns
No Engine Braking in 2nd Gear, Manual 2nd or Manual 1st
Position 250 350
Gearshift Lever Efforts High 251 351
External Leaks 252 352
Vehicle Driveability Concerns 253 353
Noise/Vibration in Forward or Reverse 254 354
Engine Will Not Crank 255 355
No PARK (P) Range 256 356
Overheating 257 357
Engagement Concern: No Forward Possible Component Reference/Action
201 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 301 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect as under Fluid Condition Check; refer to Verification of Klj . 3 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

·
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
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

·
Gasket damaged ·
Inspect for damage and install a new gasket. ·
EPC solenoid stuck or
damaged ·
Inspect for damage, contamination. Carry out EPC test in Routine
No. 203. Repair as required. Low Reverse Servo
·
Seals (piston and cover)
damaged ·
Inspect for damage. Repair as required. ·
Servo cover retaining ring
assembled incorrectly ·
Anchor pins (case)
damaged Pump Assembly
·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Porosity/cross leaks ·
Inspect pump assembly. Install new as required. ·
Gasket damaged ·
Inspect for damage and install a new gasket. ·
No. 1 and No. 2 seal rings
damaged ·
Inspect for damage. Repair as required. Reverse Clutch Assembly
·
Seals, piston damaged ·
Inspect for damage. Repair as required. ·
Check ball missing or
damaged ·
Friction elements
damaged, worn ·
Return spring piston
damaged, worn Low Reverse Band
·
Band, servo, anchor pin
damaged or worn ·
Inspect for damage. Repair as required.
Engagement Concern: Harsh Forward Possible Component Reference/Action
204 —
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 and EPC
test. 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. 304 —
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 ·
Repair as required. Klj . 7 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

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
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

Shift Concerns: Some/All Shifts Missing
Possible Component Reference/Action
210 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses, PCM,
shift solenoids, output shaft
speed (OSS) sensor, 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 ,
Go To Pinpoint Test C or
Go To Pinpoint Test E . Repair as
required. Clear DTCs, road test and repeat Self- Test. 310 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. 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. ·
Refer to the following shift routine(s) for further diagnosis:
„ Shift 1- 2, Routine 220/320
„ Shift 2- 3, Routine 221/321
„ Shift 3- 4, Routine 222/322
„ Shift 4- 3, Routine 223/323
„ Shift 3- 2, Routine 224/324
„ Shift 2- 1, Routine 225/325
Shift Concerns: Timing Concerns — Early/Late Possible Component Reference/Action
211 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, shift solenoids, EPC
solenoid, TFT sensor, 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 ,
Go To Pinpoint Test C or
Go To Pinpoint Test E . Repair as required.
Clear DTCs, road test and repeat Self- Test. 311 —
HYDRAULIC/MECHANICAL ROUTINE Other
·
Tire size change, axle ratio
change ·
Verify vehicle has original equipment. Refer to Certification
Label and Safety Standard Certification Label. Changes in tire
size or axle ratio will affect shift timing. Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Powertrain Control System
·
Engine driveability concerns ·
Refer to Routine 253. Klj . 11 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

Incorrect Pressures
·
Line pressure, EPC pressure ·
Check pressure at line and EPC taps; refer to Line Pressure
Chart for specifications. If not OK, check the main controls. If
OK, refer to the 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 Main Controls
·
EPC solenoid, stuck or
damaged hydraulically or
mechanically ·
Inspect for damage, contamination. Carry out EPC tests in
Routine No. 211. Repair as required. ·
Valves, accumulators, seals
stuck or damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
Solenoid screen blocked or
damaged ·
Clean or install a new screen.
Shift Concerns: Timing Concerns — Erratic/Hunting Possible Component Reference/Action
212 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, shift
solenoids, torque converter clutch
(TCC) solenoid, digital TR sensor,
output shaft speed (OSS) ·
Carry out Self- Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for
diagnosis. Go To Pinpoint Test A ,
Go To Pinpoint Test C or
Go To Pinpoint Test E . Repair as required. Clear
DTCs, road test and repeat Self- Test. ·
Poor engine performance ·
Refer to Routine 253. 312 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Main Controls
·
Valves, accumulators, seals,
assembled wrong, stuck or
damaged ·
Inspect for damage. Repair as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
Solenoid screen blocked or
damaged ·
Clean or install a new screen. Torque Converter Clutch
·
Torque converter ·
Refer to Torque Converter Operation Concerns:
Cycling/Shudder/Chatter Hydraulic/Mechanical Routine
342. Specific Shifts
·
Refer to the following shift routine(s) for further diagnosis: Klj . 12 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

„
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
Shift Concerns: Feel — Soft/Slipping Possible Component Reference/Action
213 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, EPC solenoid, 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 D or
Go To Pinpoint Test E . Repair as required. Clear DTCs, road test and
repeat Self- Test. ·
Engine driveability concerns ·
Refer to Routine 253. 313 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Incorrect Pressures
·
Low line pressure, low EPC
pressure ·
Check pressures at line and EPC taps; refer to Line Pressure
Chart for specifications. If pressures are low or all shifts are
soft/slipping, go to main controls. If pressures are OK and a
specific shift is soft/slipping, refer to the following 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 Main Controls
·
Main regulator valve,
overdrive servo regulator
valve stuck, damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
EPC solenoid stuck or
damaged ·
Inspect for damage and contamination. Carry out EPC tests in
Routine 213. Repair as required. Case
·
1- 2 accumulator stuck or
damaged ·
Inspect for damage. Repair as required. Filter and Seal Assembly
·
Filter plugged, damaged ·
Inspect for damage. Install a new filter as required. ·
Seal damaged or cut ·
Inspect for damage. Replace as required. Klj . 13 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

Shift Concerns: Feel —
Harsh Possible Component Reference/Action
214 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, EPC solenoid, 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 D or
Go To Pinpoint Test E . Repair as required. Clear DTCs, road test and
repeat Self- Test. ·
Engine driveability concerns ·
Refer to Routine 253. 314 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Incorrect Pressures
·
High line pressure, high EPC
pressure ·
Check pressures at line and EPC taps. See the to Line Pressure
Chart for specifications. If pressures are high or all shifts are
harsh, go to Main Controls. If pressures are OK and a specific
shift is harsh, 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 Main Controls
·
Main regulator valve,
overdrive servo regulator
valve stuck, damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
EPC solenoid stuck or
damaged ·
Inspect for damage or contamination. Carry out EPC tests in
Routine 214. Repair as required.
Shift Concerns: No 1st Gear, Engages In Higher Gear Possible Component Reference/Action
215 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, shift
solenoids, digital transmission
range 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. 315 —
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. Klj . 14 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

vehicle wiring harnesses,
PCM, shift solenoids,
OSS 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. ·
Poor engine performance ·
Refer to Routine 253. 320 —
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
·
Intermediate clutch
pressure, line pressure ·
Check pressure at line and intermediate clutch taps; see the line
pressure chart for specifications. If not OK, check the main controls. Main Controls
·
1- 2 shift valve, stuck or
damaged ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specification. ·
Shift solenoid SSA
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. ·
Gasket damaged ·
Inspect for damage and install a new gasket. ·
No. 8 ball not seating ·
Inspect for damage. Repair as required. Case
·
1- 2 accumulator stuck or
damaged ·
Inspect for damage. Repair as required. Pump
·
Porosity/cross leaks,
balls missing, damaged
or leaking ·
Inspect for porosity/leaks, balls missing. Install a new pump as
required. ·
Gasket damaged ·
Inspect for damage and install a new gasket. Intermediate Clutch
Assembly
·
Seals damaged ·
Inspect for damage. Repair as required. ·
Piston damaged ·
Inspect for damage. Repair as required. ·
Friction elements
damaged or worn ·
Inspect for damage. Repair as required. Intermediate One-
Way
Clutch Assembly ·
Not holding or damaged ·
Inspect for damage. Repair as required. Planetary One-
Way Clutch
Assembly ·
Not overrunning or
damaged ·
Inspect for damage. Repair as required. 1-
2 Accumulator ·
Damaged accumulator ·
Inspect for damage. Repair as required. Klj . 17 ba
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...

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
312003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2748/S3B~us~en~ ...