engine FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Disc and Pressure Plate —
4.6L (4V) Engine
1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Remove the transmission. For additional information, refer to Section 308 - 03C .
3. Remove the starter. 1. Remove the terminal cap.
2. Remove the nuts.
3. Remove the wires and position them aside.
4. Remove the two bolts and the starter.
4. Remove the clutch cable clip, then pull the cable through the clutch housing.
SECTION 308-
01: Clutch 2003 Mustang Workshop Manual Special Tool(s)
Clutch Aligner
308-
020 (T74P-7137- K)
Material Item Specification
Premium Long Life Grease
XG
-1-C ESA-
M1C75- B Klj . 1 ba
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REMOVAL AND INSTALLATION
Pilot Bearing
1. Remove the clutch disc and the clutch pressure plate. For additional information, refer to Disc and Pressure Plate — 3.8L and 4.6L (2V) Engines or
Disc and Pressure Plate — 4.6L (4V) Engine
in this section.
2. Using the special tool, remove the pilot bearing from the flywheel.
Installation 1. Insert the pilot bearing into the crankshaft.
2. Install the clutch disc and the clutch pressure plate. For additional information, refer to Disc and Pressure Plate — 3.8L and 4.6L (2V) Engines or
Disc and Pressure Plate — 4.6L (4V) Engine in
this section.
SECTION 308-
01: Clutch 2003 Mustang Workshop Manual Special Tool(s)
Puller with Slide Hammer
308-
001 (T58L-101- B) Klj . 1 ba
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The clutch control system engages and disengages the clutch. The clutch control system disengages
the clutch when the clutch pedal is depressed and engages the clutch when the clutch pedal is
released. Clutch pedal motion is transmitted by the clutch release lever cable to the clutch release
lever. The clutch release hub and bearing engages the clutch pressure plate diaphragm spring,
releasing the pressure on the clutch disc which in turn disengages the transmission from the engine.
The clutch adjusts automatically to compensate for clutch disc wear. The clutch linkage is self-
adjusting.
The clutch pedal position (CPP) switch prevents the starter motor from engaging unless the clutch
pedal is depressed all the way to the floor. The switch plunger is contacted by the clutch pedal and
extends as the clutch pedal is pressed. The clutch pedal position switch is electrically connected in line
with the ignition switch and the starter motor relay coil. The CPP also turns off the speed control when
the clutch pedal is depressed. 4 7L583 Clutch pedal quadrant and pawl assembly Klj . 2 ba
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REMOVAL AND INSTALLATION
Clutch Pedal —
Quadrant and Pawl Assembly
Removal 1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414 -
01 .
2. Loosen the nut from inside the engine compartment.
3. Loosen the nuts from inside the vehicle.
4. Loosen the screw.
5. Disconnect the brake pedal position (BPP) switch electrical connector.
SECTION 308-
02: Clutch Controls 2003 Mustang Workshop Manual Klj . 1 ba
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13. Remove the self-
adjusting mechanism.
14. Remove the self- adjusting mechanism shaft bushings.
Installation 1. NOTE: Before the installation of the clutch pedal shaft or clutch pedal, remove and inspect the
brake and clutch pedal bushings. Clean and lubricate with a light film of engine oil meeting Ford
specification WSS- M2C153-G and replace the brake and clutch pedal bushing if excessive wear
is evident.
To install, reverse the removal procedure. Klj . 4 ba
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SPECIFICATIONS
SECTION 308-
03A: Manual Transaxle/Transmission — T5OD 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
Multi-
Purpose Grease
D0AZ- 19584- AA ESB-
M1C93- B Threadlock and Sealer
E0AZ-
19554- AA WSK-
M2G351- A5 Clear Silicone Rubber
D6AZ-
19562- AA ESB-
M4G92- A Pipe Sealant with Teflon®
D8AZ-
19554- A ESR-
M18P7-A MERCON® Multi-
Purpose ATF Transmission Fluid
XT -2-QDX Mercon®
Preload
Output shaft preload 0.0127 mm ( 0.0005 in) - 0.1016 mm ( 0.004 in)
Synchronizer
Synchronizer blocking ring to conical face runout 0.5 mm (0.02 in)
End Play
Countershaft cluster gear end play 0.0254 mm ( 0.001 in) -
0.127 mm ( 0.005 in) Output shaft end play 0.0127 mm ( 0.0005 in) - 0.1016 mm ( 0.004 in)
Torque Specifications Description Nm lb-
ft lb-
in Bolt retaining gearshift lever to extension housing 18 13 —
Screw retaining inner shift boot to floor pan 10 — 89
Bolt retaining gear shift lever to gear shift stub shaft 37 27 —
Bolt retaining OSS to case 10 — 89
Bolt retaining countershaft rear bearing retainer to case 21 15 —
Shift lever reverse pin 40 30 —
Reversing lamp switch 37 27 —
Bolt retaining case cover to case 12 9 —
Bolt retaining extension housing to case 54 40 —
Bolt retaining input shaft bearing retainer to case 21 15 —
Drain plug 23 17 —
Bolt retaining transmission to block 75 55 —
Bolt retaining engine plate to transmission 27 20 — Klj . 1 ba
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SPECIFICATIONS
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
Premium Long-
Life Grease
XG -1-C, K or T ESA-
M1C75- B Threadlock and Sealer
E0AZ-
19554- AA WSK-
M2G351- A5 Black Silicone Rubber
D6AZ-
19562- BA ESB-
M4G92- A Pipe Sealant with Teflon®
D8AZ-
19554- A ESR-
M18P7- A Motorcraft MERCON® Multi-Purpose (ATF)
Transmission Fluid
XT -2-QDX MERCON®
Synchronizer
Synchronizer blocking ring to conical face runout 0.5 mm (0.02 in)
End Play
Input shaft end play 0.02286 mm (0.0009 in) -
0.0508 mm
(0.002 in) Countershaft cluster gear end play 0.0 mm (0.0 in) -
0.076 mm (0.003 in) Output shaft end play 0.0012 mm (0.0005 in) -
0.100 mm (0.004
in)
Torque Specifications Description Nm lb-
ft lb-
in Gearshift lever to extension housing bolt 23 13 —
Gear shift lever to gear shift stub shaft bolt 37 27 —
OSS to case bolt 10 — 89
Reverse idler gear bolt 27 20 —
Fifth/reverse lockout bolt 20 15 —
Clutch housing to transmission main case bolt 31 23 —
Extension housing to transmission main case bolt 31 23 —
Drain plug 23 17 —
Reversing lamp switch 37 27 —
Fill plug 17 13 —
Transmission to engine bolt 75 55 —
Engine plate to transmission bolt 27 20 —
Crossmember to frame bolt 41 30 — Klj . 1 ba
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DESCRIPTION AND OPERATION
Exhaust System
WARNING: The normal operating temperature of the exhaust system is very high. Never
attempt to repair any part of the system until it has cooled. Be especially careful when working
around the three way catalytic converter. The temperature of the three way catalytic converter
rises to a high level after only a few minutes of engine operation.
CAUTION: When repairing exhaust system or removing exhaust components, disconnect
all heated oxygen sensors (HO2S) at the wiring connectors to prevent damage to the heated
oxygen sensors and wiring harness. For additional information, refer to Section 303 - 14 for
location of the heated oxygen sensors.
The exhaust system:
zcontains dual three- way catalytic converters.
z has a crossover pipe downstream of the three way catalytic converters (4.6L).
z has two upstream heated oxygen sensors mounted before the three- way catalytic converters.
z the production muffler and tailpipe assembly is a one- piece design exhaust system.
Exhaust System — 3.8L Exhaust System — 4.6L (2V) SECTION 309-
00: Exhaust System 2003 Mustang Workshop Manual Item Part Number Description
1 5F250 Dual converter assembly
2 5D255 Insulator bracket assembly
3 5A246 Insulator bracket, (tailpipe)
4 5D255 Insulator bracket assembly
5 5232 Muffler Klj . 1 ba
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SPECIFICATIONS
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual General Specifications
Item Specification
Fuel tank capacity 59.42 liters (15.7 gallons)
Key on, engine off fuel pressure 207-
345 kPa
(30-50 psi) Engine running fuel pressure (idle) 152-
255 kPa
(27-37 psi) Lubricants
SAE 5W-
20 Super Premium Synthetic Blend Motor Oil XO-5W20- QSP WSS-
M2C153- H Klj . 1 ba
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GENERAL PROCEDURES
Pressure Relief
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel- related components. Highly flammable mixtures are always present
and may be ignited, resulting in possible personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is
not running. Before servicing or disconnecting any of the fuel lines or fuel system components,
the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing
personal injury or a fire hazard.
1. Remove the Schrader valve cap and install the Fuel Pressure Gauge.
2. CAUTION: Open the manual valve slowly on the Fuel Pressure Gauge.
Relieve the fuel pressure. zPlace the fuel in a suitable container.
SECTION 310-
00: Fuel System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Fuel Pressure Gauge
310-
012 (T80L-9974- B) Klj . 1 ba
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