AC system FORD MUSTANG 2003 Workshop Manual

PINPOINT TEST B: THE CONVERTIBLE TOP HESITATES/COMES UP
UNEVEN z
Is the resistance less than 5 ohms? A15 CHECK CIRCUIT 903 (RD) FOR AN OPEN
z
Disconnect: Raise Relay C4063.
z Measure the resistance between raise relay C4063 pin 30, circuit
903 (RD), harness side and convertible top motor C4062, circuit
903 (RD), harness side.
z Is the resistance less than 5 ohms? Yes
INSTALL a new raise
relay. TEST the
system for normal
operation.
No
REPAIR the circuit.
TEST the system for
normal operation.
A16 CHECK THE RAISE INPUT TO THE MOTOR
z
Key in ON position.
z Depress and hold the convertible top switch in the RAISE position.
z Measure the voltage between convertible top motor C4062, circuit
903 (RD), harness side and ground.
z Is the voltage greater than 10 volts? Yes
INSTALL a new
convertible top motor;
REFER to
Hydraulic System, Lift Cylinder
and Motor in this
section. TEST the
system for normal
operation.
No
INSTALL a new raise
relay. TEST the
system for normal
operation. Test Step Result / Action to Take
B1 CHECK THE CONVERTIBLE TOP UP/DOWN
OPERATION NOTE:
The parking brake must be applied for the Yes Klj . 7 ba
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PINPOINT TEST C: THE CONVERTIBLE TOP DOES NOT RAISE OR
DOES NOT GO UP ALL THE WAY
PINPOINT TEST D: THE CONVERTIBLE TOP HYDRAULIC SYSTEM convertible top system to operate.
z Key in ON position.
z Actuate the convertible top switch to the LOWER
and RAISE positions.
z Did the convertible top operate to the full down
and full up position without hesitating? ADJUST the convertible top linkage.
TEST the system for normal
operation.
No
GO to
B2 .
B2 CHECK THE MOTOR OPERATION
z
Gain access to the convertible top motor/pump
assembly.
z Operate the convertible top to the LOWER and
RAISE positions while listening to the motor.
z Did the motor stop and then continue at any
time? Yes
Go To Pinpoint Test A
.
No
GO to B3 .
B3 CHECK THE CONVERTIBLE TOP LINKAGE
z
Operate the convertible top to the LOWER and
RAISE positions while observing the convertible
top linkage.
z Did the linkage operate smoothly without
binding? Yes
Go To Pinpoint Test D
.
No
ADJUST the convertible top linkage.
TEST the system for normal
operation. Test Step Result / Action to Take
C1 CHECK THE CONVERTIBLE TOP OPERATION
NOTE:
The parking brake must be applied for the
convertible top system to operate.
z Key in ON position.
z Actuate the convertible top switch to the RAISE
position.
z Did the motor operate? Yes
GO to
C2 .
No
Go To Pinpoint Test A .
C2 CHECK THE CONVERTIBLE TOP LINKAGE
z
Operate the convertible top to the LOWER and
RAISE positions while observing the convertible
top linkage.
z Did the linkage bind and prevent the
convertible top from raising? Yes
ADJUST the convertible top linkage.
TEST the system for normal
operation.
No
Go To Pinpoint Test D
.
Test Step Result / Action to Take
D1 CHECK THE FLUID LEVEL
NOTE:
The fluid level should be even
with the bottom of the filler plug hole.
NOTE: Place an absorbent cloth
below the filler plug when checking
the fluid level.
z Remove the filler plug and check the Yes
GO to
D3 .
No
GO to D2 . Klj . 8 ba
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fluid level.
z Is the fluid level OK? D2 CHECK THE HYDRAULIC SYSTEM
FOR LEAKS z
Inspect all fittings and hoses for leaks.
z Are any leaks noticed? Yes
REPAIR the leaking fittings or INSTALL new
hoses as necessary. TEST the system for normal
operation.
No
GO to
D3 .
D3 BLEED THE HYDRAULIC SYSTEM
z
Bleed the hydraulic system. Refer to
System Bleeding in this section.
z Does the system operate correctly
after bleeding? Yes
OPERATE the convertible top up and down three
times. INSPECT the hydraulic system for leaks or
loss of fluid. REPAIR as necessary if loss of fluid
is detected.
No
GO to
D4 .
D4 CHECK THE CONVERTIBLE TOP
z
Remove the hydraulic system from
the vehicle. Refer to Hydraulic System, Lift Cylinder and Motor in this
section.
z Operate the convertible top assembly
up and down manually.
z Does the convertible top bind? Yes
ADJUST the convertible top. INSTALL the
hydraulic system; REFER to
Hydraulic System, Lift Cylinder and Motor in this section. TEST the
system for normal operation.
No
GO to D5 .
D5 CHECK THE HYDRAULIC SYSTEM
OUT OF THE VEHICLE z
Bleed the hydraulic system. Refer to
System Bleeding in this section.
z Does the system operate correctly
after bleeding? Yes
CHECK all fittings and hoses for leaks. REPAIR
as necessary if loss of fluid is detected. INSTALL
the hydraulic system; REFER to
Hydraulic System, Lift Cylinder and Motor in this section.
TEST the system for normal operation.
No
GO to D6 .
D6 CHECK THE LIFT CYLINDERS
z
Operate the hydraulic system using a
12 volt power source.
z Did the lift cylinders extend and
retract? Yes
INSTALL a new motor/pump assembly. REFER to
Hydraulic System, Lift Cylinder and Motor
in this
section. TEST the system for normal operation.
No
INSTALL a new lift cylinder. REFER to Hydraulic System, Lift Cylinder and Motor in this section.
TEST the system for normal operation. Klj . 9 ba
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GENERAL PROCEDURES
System Bleeding
1. If required, remove the hydraulic system from the vehicle. Refer to Hydraulic System, Lift Cylinder and Motor in this section.
2. Remove the fill plug at the end of the hydraulic pump.
3. Fill the pump with Mercon® Multi- Purpose Automatic Transmission Fluid XT -2-QDX or
equivalent to the bottom of the fill hole and install the fill plug.
4. NOTE: Some noise squeal may be noticed due to the air in the system.
Connect a 12- volt power source to the motor connector and operate the motor until the
cylinders are fully extended. Reverse the 12- volt connection to fully retract the cylinders. Repeat
this procedure three times.
5. Remove the fill plug and check the fluid level. Fill the pump with MERCON® Multi- Purpose
Automatic Transmission Fluid XT -2-QDX or equivalent to the bottom of the fill hole.
SECTION 501-
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6. Install a fill plug.
7. Install the hydraulic system in the vehicle. Refer to
Hydraulic System, Lift Cylinder and Motor in
this section. Klj . 2 ba
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opposite direction will have the opposite effect.
NOTE:
Turn the adjusting cam one notch at a time.
Adjust the adjusting cam as needed. 1. Remove the cam stop set screw.
2. Rotate the adjusting cam.
3. Install the cam stop set screw.
5. Make sure the convertible top operate correctly.
6. Install the quarter trim panel. For additional information, refer to Section 501 - 05 .
7. Close the convertible top.
Convertible Top Lifts Up Unevenly — Lift Cylinder and C-pivot Inspection
8. Remove the quarter trim panel. For additional information, refer to Section 501 - 05 .
9. NOTE: This step applies to vehicles equipped with the Mach sound system.
Remove the screws and disconnect the electrical connectors.
10. Remove the screws. Klj . 2 ba
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If one rod bottoms out 25mm (1 inch) or more before the other, the lagging lift cylinder may be
bent and will need to be replaced.
16. With the lift cylinder rods retracted, manually lower the convertible top.
17. Manually lift each side rail 7.5- 10 cm (3-4 inches) to check for obvious binding. Side arms
should have equal resistance, side- to-side. If the resistance is noted, loosen the clamp load of
the c- pivot rivet with using a center pinch. If a dramatic resistance is still noted replace the c-
pivot rivet with shoulder bolt kit (F5ZZ-76539A04- A).
18. Position the lift cylinders and install the nuts.
19. Install the two cylinder rod mounting bolts.
20. Install the speakers. For additional information, refer to Section 415 - 03 .
21. Install the screws.
NOTE: This step applies to vehicles equipped with the Mach sound system.
22. Install the screws and connect the electrical connectors. Klj . 4 ba
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REMOVAL AND INSTALLATION
Hydraulic System, Lift Cylinder and Motor
Removal
NOTE:
The convertible top hydraulic components are removed from the vehicle as an assembly. The
hydraulic components are individually repaired and the system must be bled before being installed into
the vehicle.
Hydraulic system
1. Unlatch the convertible top.
2. Remove the rear quarter trim panel. For additional information, refer to Section 501 - 05 .
3. NOTE: This step applies to vehicles equipped with the Mach sound system.
Remove the screw and disconnect the electrical connectors.
4. Remove the screws.
5. Remove the speakers.
6. Remove the two cylinder rod mounting bolts.
SECTION 501-
18: Convertible Top 2003 Mustang Workshop Manual Klj . 1 ba
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NOTE:
Make sure that the tetra seal is installed in the bottom of each of the folding top
hydraulic cylinder ports before attaching the upper and lower hose fittings.
Install the hydraulic lines using a thread locker onto the lift cylinder.
Motor assembly 2. NOTE: Be sure that each fitting is installed in the correct position on the folding top hydraulic
component.
Install the hydraulic lines using a thread locker onto the motor assembly.
Hydraulic system 3. Bleed the hydraulic system. For additional information, refer to System Bleeding in this section.
4. Install the motor and cylinders as an assembly.
5. Position the motor assembly.
6. Connect the motor electrical connector. Klj . 4 ba
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12.
NOTE: This step applies to vehicles equipped with the Mach sound system.
Install the screw and connect the electrical connectors.
13. Install the rear quarter trim panel. For additional information, refer to Section 501 - 05 .
14. Latch the convertible top. Klj . 6 ba
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