convertible FORD MUSTANG 2003 Workshop Manual

Positions 5 through 7 indicate vehicle line, series and body type.
zP40 — Two-door coupe
z P42 — Two-door coupe, GT (Mach One available in GT Coupe only)
z P44 — Two-door convertible
z P45 — Two-door convertible, GT
z P48 — Two-door coupe, Cobra
z P49 — Two-door convertible, Cobra
Engine Code
The eighth VIN position is the engine displacement and number of cylinders code.
z4 — 3.8L, OHV, EFI, six cylinder
z R — 4.6L, DOHC, EFI, eight cylinder (Mach One)
z X — 4.6L, SOHC, EFI, eight cylinder
z Y— 4.6L, DOHC, S/C, EFI, eight cylinder (Cobra) Computer Generated Check Digit Klj . 3 ba
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The interior trim codes are listed below. The first letter/number is for the interior fabric. The second
letter is for the interior color.
z9 — Quantum/Rhodes cloth (base coupe)
z A — Link weave cloth (Mach One)
z M — Nudo Leather (Cobra)
z T — Lea cloth with vinyl (base coupe/convertible)
z U — Shadow/Twill cloth (GT)
z X — Lea cloth with vinyl (GT)
The interior trim colors are:
z2 — Medium Graphite
z 2 — Medium Graphite/Midnight Black (Cobra)
z H — Medium Parchment
z H — Midnight Black/Medium Parchment (Cobra)
z R — Midnight Black/Colorado Red (Cobra)
z W — Midnight Black
z Z — Oxford White
Tape/Paint Stripe Codes
zP — White/Gray (tape applique emblem)
z X — Black (hood and body tape stripe) — Mach One Radio Codes Klj . 9 ba
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DESCRIPTION AND OPERATION
Jacking
WARNING: Never run the engine with one wheel off the ground, such as when changing a
tire. The wheel still on the ground could cause the vehicle to move.
CAUTION: The jack (17080) provided with the vehicle is intended to be used in an
emergency for changing a deflated tire. To avoid damage to the vehicle, never use the jack to
lift the vehicle for any other purpose. Refer to the Owner Guide when using the jack supplied
with the vehicle.
CAUTION: Under no circumstances should the vehicle ever be lifted by the suspension
arm brackets, rear stabilizer or differential housing or convertible cross brace. Severe damage
to the vehicle could result.
CAUTION: Do not attempt to use jack pressure on either the front bumper (17757) or the
rear bumper (17906) of any vehicle. Damage to the bumper covers will occur.
Lift the vehicle using the Jacking Points procedure in this section.
Jacking Points
To lift the front or either side of the front end, position the floor jack under the front frame lift points. SECTION 100-
02: Jacking and Lifting 2003 Mustang Workshop Manual Klj . 1 ba
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DESCRIPTION AND OPERATION
Lifting
CAUTION: Do not allow the lift adapters to contact the steering linkage, suspension arms,
stabilizer arms, or to compress the lower suspension arm stabilizer bar insulator (5493).
Damage to the suspension, exhaust and steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
CAUTION: Never use the differential housing as a lift point. Damage to the differential
housing and cover may occur.
CAUTION: Do not lift vehicle on rocker panel pinch flange or convertible cross brace.
Body damage may occur.
Lift the vehicle using the Lifting Points procedure in this section.
Lifting Points—Drive On Lift
CAUTION: To prevent possible damage to the underbody, do not drive the vehicle onto
the drive on lift without first checking for possible interference.
Check for interference between the upright flanges of the hoist rails and the underbody.
If an interference exists, modify the hoist flanges or build up the approach ramps as necessary to
provide clearance. Lifting Points — Frame Contact Lift, Single Post Lift, Two Post Lift SECTION 100-
02: Jacking and Lifting 2003 Mustang Workshop Manual Klj . 1 ba
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CAUTION: Do not position lift pads under the No. 3 crossmember.
CAUTION: Do not lift vehicle on rocker panel pinch flange or convertible cross brace.
Body damage may occur.
NOTE: Adapters may be necessary to clear vehicle components to lift the vehicle safely. The adapters
must be placed at the four designated contact points. Position the adapters so they are center on the
adapter contact area.
Lift the vehicle at the applicable lift points. Klj . 2 ba
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z
Body panel misaligned
(exposed edge). z
REALIGN the appropriate
body panel.
z Hood misaligned (front
margin). z
CHECK hood gaps and fit.
ADJUST the hood as
necessary.
z Front grille edge noise. zAPPLY foam in the hollow
areas behind the louvers.
z Wind noise
created by grille
opening panel z
Grille relationship to
leading edge on hood. z
ADJUST the grille
opening panel forward to
eliminate wind noise.
z Sharp edges due to
material imperfections. z
REMOVE the sharp
edges (no damage to
visible surface).
z Wind noise from
air extractor z
Air extractor housing
seated incorrectly. z
REINSTALL the air
extractor housing.
z Air extractor housing or
flaps damaged. z
INSTALL a new air
extractor.
z Air leak at top of
A-pillar —
vehicles with a
convertible top z
Seal at windshield
header installed
incorrectly. z
REINSTALL the seal.
z Seal pinched. zFILL the seal with foam to
reshape it.
z Gap between side rail
and header seal at A-
pillar. z
ADJUST the J-hook/vinyl
top.
z Air leak at rear
quarter glass
(division bar) —
vehicles with a
convertible top z
No contact between
front side glass and
quarter glass division
bar. z
ADJUST the front side
glass regulator and the
rear quarter glass
regulator.
z Air leak or wind
noise from top of
side glass —
vehicles with a
convertible top z
Gap between side rail
and vinyl top. z
ADD additional foam tape
to seal between the side
rail and the vinyl top.
z Seal at windshield
header installed
incorrectly. z
REINSTALL the seal.
z Seal damaged
between side rail and
vinyl top. z
INSTALL a new seal.
z Vinyl top damaged. zINSPECT the vinyl top.
INSTALL a new vinyl top
as necessary.
z Air leak or wind
noise at
windshield
header —
vehicles with a
convertible top z
Vinyl top not flush with
header. z
ADJUST the J-hook to
lower the top to achieve a
flush condition.
z Seal at windshield
header installed
incorrectly. z
REINSTALL the seal.
z Header seal not flush zREINSTALL the seal. Klj . 15 ba
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with header.
z Convertible top
flapping with the
top up z
Vinyl top contacting
interior headliner. z
Working from front to
back, INSTALL a 6.35 mm
(0.25 in) foam sheet
between the headliner
and the vinyl top at the
suspected area. Allow a
clearance of 50 mm (2 in)
-75 mm (3 in) away from
the roof bows and the side
rails.
z Noise from roof
rack z
Roof rack rails or
crossbars loose. z
TIGHTEN the fasteners.
z Roof rack fasteners
missing. z
INSTALL the approved
fasteners.
z Roof rack crossbars
installed backward. z
REINSTALL the
crossbars.
z Roof rack rub strips
partially lifting from
roof. z
REAPPLY adhesive or
fasteners or INSTALL new
rub strips as necessary.
z Roof rack gaskets
loose or misaligned. z
REINSTALL the gasket.
z Wind noise from
bug
shield/exterior
windshield sun
visor z
Turbulence created by
location and shape. z
REMOVE per customer
direction if it is a dealer
installed option. Symptom Chart—
Brake Noise/Vibration Condition
Possible Sources Action
z Rattling noise zCaliper
mounting bolts
loose. z
CHECK the caliper bolts.
TIGHTEN to specifications.
REFER to Section 206 - 03
for front disc brakes or
Section 206
- 04 for rear
disc brakes.
z Damaged or
worn caliper
pins or
retainers. z
CHECK the caliper pins
and retainers for lubrication
and correct fit. LUBRICATE
or INSTALL new
components as necessary.
z Missing or
damaged anti-
rattle clips or
springs. z
CHECK the brake pads for
missing clips or broken
springs. INSTALL new
components as necessary.
REFER to Section 206 - 03
for front disc brakes or
Section 206
- 04 for rear
disc brakes.
z Loose brake
disc shield. z
TIGHTEN the brake disc
shield bolts to specification.
REFER to Section 206 - 03 .
z Clicking noise— with
brakes applied with
ABS brakes z
ABS hydraulic
control unit. z
Acceptable condition.
z Squealing noise— zDisc brake zAcceptable condition. Klj . 16 ba
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PINPOINT TEST C: CONTINUOUS SEEK/SCAN IN AM/FM
PINPOINT TEST D: NO SOUND FROM ONE OR MORE OF THE
SPEAKERS —
NOT ALL SPEAKERS z
Is the noise eliminated? jumper cable. When noise is eliminated,
PROVIDE a permanent ground where
necessary. TEST the system for normal
operation.
Test Step Result / Action to Take
C1 CHECK OPERATION OF THE
SEEK/SCAN FUNCTIONS z
Key in ON position.
z Operate the SEEK/SCAN functions
with the audio unit in both AM and FM
tuner modes.
z Do the SEEK/SCAN functions
search continuously? Yes
GO to
C2 .
No
The system is OK. C2 CHECK ANTENNA FOR DAMAGE
z
Key in OFF position.
z Disconnect: Antenna Lead Terminal.
z Measure the resistance between the
antenna cable lead terminal and the
end of the antenna grid wire.
z Is the resistance less than 8 ohms? Yes
GO to
C3 .
No
REPAIR the antenna. REFER to Section 415 - 02
C3 SUBSTITUTE ANTENNA EXTENSION
CABLE z
Substitute a known good antenna
cable between the audio unit and the
antenna.
z Key in START position.
z Check the operation of the audio unit.
z Is the noise eliminated? Yes
INSTALL a new antenna extension cable. REFER
to
Section 415 - 02 . TEST the system for normal
operation.
No
REINSTALL the original cable. REMOVE the
audio unit and SEND it to an authorized Ford
audio system repair facility. TEST the system for
normal operation. Test Step Result / Action to
Take D1 CHECK FOR SOUND
z
Key in ON position.
z Turn on the audio unit.
z Are all speakers without sound? Yes
GO to
Pinpoint Test E .
No
For convertible,
GO to D2 .
For coupe, GO to
D4 . Klj . 7 ba
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For Mach 1000
subwoofer
speakers,GO to
D8
.
D2 CHECK CIRCUITS BETWEEN THE AFFECTED SPEAKER(S) AND
SUBWOOFER AMPLIFIERS z
Disconnect: Subwoofer Amplifier C4108a.
z Disconnect: Subwoofer Amplifier C4109b.
z Disconnect: Affected Speaker(s).
z Measure the resistance between the subwoofer amplifier and the
affected speaker(s) and between the subwoofer amplifier and ground
as follows:
z Are the resistances less than 5 ohms between the subwoofer
amplifier and the affected speaker(s) and greater than 10,000
ohms between the subwoofer amplifier and ground? Speaker Circuits Affected Speaker Pin Subwoofer Amplifier Pin Circuit
RF 1 (convertible only) LH 7 822 (BK/LG)
RF 2 (convertible only) LH 8 287 (BK/WH)
LF 1 (convertible only) LH 7 822 (BK/LG)
LF 2 (convertible only) LH 8 287 (BK/WH)
RR 1 RH 7 822 (BK/LG)
RR 2 RH 8 287 (BK/WH)
LR 1 RH 7 822 (BK/LG)
LR 2 RH 8 287 (BK/WH) Yes
GO to
D3 .
No
REPAIR the circuit
(s) in question.
TEST the system
for normal
operation. D3 CHECK CIRCUITS BETWEEN THE AUDIO UNIT AND THE
SUBWOOFER AMPLIFIERS z
Disconnect: Audio Unit C290b.
z Disconnect: Subwoofer Amplifier C4108a.
z Disconnect: Subwoofer Amplifier C4109b.
z Measure the resistance between the subwoofer amplifier and the
audio unit C290b and between the subwoofer amplifier and ground
as follows:
z Are the resistances less than 5 ohms between the subwoofer
amplifier and the audio unit and greater than 10,000 ohms
between the subwoofer amplifier and ground? Speaker Circuits Audio Unit C290b Pin Subwoofer Amplifier Pin Circuit
2 LH 5 167 (BN/OG)
6 RH 5 169 (LG/BK)
1 LH 6 168 (RD/BK)
5 RH 6 172 (LB/RD) Yes
GO to
D6 .
No
REPAIR the circuit
(s) in question.
TEST the system
for normal
operation. D4 CHECK CIRCUITS BETWEEN THE AFFECTED SPEAKER(S) AND
SUBWOOFER AMPLIFIER z
Disconnect: Subwoofer Amplifier C4109b.
z Disconnect: Affected Speaker(s).
z Measure the resistance between the subwoofer amplifier and the Yes
GO to
D5 . Klj . 8 ba
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PINPOINT TEST F: POOR QUALITY SOUND FROM ONE OR MORE
SPEAKERS (NOT ALL SPEAKERS) No
GO to
Pinpoint Test D .
Test Step Result / Action to
Take F1 CHECK SOUND QUALITY
z
Key in ON position.
z Turn on the audio unit.
z Carry out the speaker walk- around test by pressing preset buttons 3
and 6 simultaneously.
z Do all speakers have poor sound quality? Yes
REMOVE the
audio unit and
SEND it to an
authorized Ford
audio system
repair facility.
TEST the system
for normal
operation.
No
For convertible,
GO to
F2 .
For coupe, GO to
F4 .
For Mach 1000
subwoofer
speakers,GO to
F6 .
F2 CHECK CIRCUITS BETWEEN AFFECTED SPEAKER(S) AND
SUBWOOFER AMPLIFIERS z
Disconnect: Subwoofer Amplifier C4108a.
z Disconnect: Subwoofer Amplifier C4109b.
z Disconnect: Affected Speaker(s).
z Measure the resistance between the subwoofer amplifier and the
affected speaker(s) and between subwoofer amplifier and ground as
follows:
z Are the resistances less than 5 ohms between the subwoofer
amplifier and the affected speaker(s) and greater than 10,000 Speaker Circuits Affected Speaker Pin Subwoofer Amplifier Pin Circuit
RF 1 (convertible only) LH 7 822 (BK/LG)
RF 2 (convertible only) LH 8 287 (BK/WH)
LF 1 (convertible only) LH 7 822 (BK/LG)
LF 2 (convertible only) LH 8 287 (BK/WH)
RR 1 RH 7 822 (BK/LG)
RR 2 RH 8 287 (BK/WH)
LR 1 RH 7 822 (BK/LG)
LR 2 RH 8 287 (BK/WH) Yes
GO to
F3 .
No
REPAIR the circuit
(s) in question.
TEST the system
for normal
operation. Klj . 13 ba
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