sensor FORD MUSTANG 2003 Workshop Manual

WOT
The acronym for wide open throttle is WOT.
Tools and Techniques
Electronic Vibration Analyzer (EVA)
The EVA is a hand-
held electronic diagnostic tool which will assist in locating the source of
unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the three most common vibration frequencies and their
corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative
signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is
arranged to make the EVA simple to program and use. Some of the functions include the ability to
average readings as well as record, play back and freeze readings. The EVA has a strobe balancing
function that can be used to detect imbalance on rotating components such as a driveshaft or engine
accessories.
The EVA allows for a systematic collection of information that is necessary to accurately diagnose and
repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel. „If the condition is felt through the steering wheel, the source is most likely in the front of
the vehicle.
„ A vibration that is felt in the seat or floor only will most likely be found in the driveline,
drive axle or rear wheels and tires.
c. Record the readings. Also note when the condition begins, when it reaches maximum intensity, and if it tends to diminish above/below a certain speed.
„Frequencies should be read in the "average" mode. Item Description
1 EVA screen
2 Frequency mode displayed in rpm or Hz
3 Active sensor input (A or B)
4 Current active mode
5 G force indicators or the strongest frequencies in descending strength of each vibration
6 Strength of each vibration
7 Frequency in rpm/Hz of each vibration Klj . 11 ba
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„
Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an
8 Hz through 12 Hz.
d. Place the vibration sensor on or near the suspect area outside the vehicle.
e. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading.
f. Compare the readings.
„A match in frequency indicates the problem component or area.
„ An unmatched test could indicate the concern is caused by the engine, torque converter,
or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related.
„ Example: A vibration is felt in the seat. Place the sensor on the console. Record the
readings. Place the vibration sensor on the rear axle. Compare the readings. If the
frequencies are the same, the axle is the problem component.
Vibrate Software®
Vibrate Software® ( Rotunda tool number 215- 00003) is a diagnostic aid which will assist in pinpointing
the source of unacceptable vibrations. The engine's crankshaft is the point of reference for vibration
diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as
the engine's crankshaft. Vibrate Software® calculates the angular velocity of each component and
graphically represents these velocities on a computer screen and on a printed vibration worksheet.
The following steps outline how Vibrate Software® helps diagnose a vibration concern:
zEnter the vehicle information. Vibrate will do all the calculations and display a graph showing
tire, driveshaft and engine vibrations.
z Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
z Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific
component group causing the concern.
„An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will
be needed.
z Provide pictures of diagnostic procedures to aid in testing components.
Combination EngineEAR/ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while
the vehicle is being road tested. The ChassisEARs can identify the noise and location of
damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings.
EngineEAR Basic Unit
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the
noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering
pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for
detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional
sensing tip is used to listen to the various components. Point the sensing tip at the suspect component
and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal
structure-borne noise and vibrations, generated by or passing through, the component. Various
volume levels can reveal different sounds.
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where
there is weather- stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks Klj . 12 ba
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noise—
normally
accompanied by
vibration Powertrain/Drivetrain Mount Neutralizing in this
section.
z Damaged or
misaligned exhaust
system. z
INSPECT the exhaust
system for loose or broken
clamps and brackets.
CARRY OUT Exhaust System Neutralizing in this
section.
z Whistling noise—
normally
accompanied
with poor idle
condition z
Air intake system. zCHECK the air intake
ducts, air cleaner, throttle
body and vacuum hoses for
leaks and correct fit.
REPAIR or ADJUST as
necessary. REFER to
Section 303 - 12
z
Clunking noise zWater pump has
excessive end play or
imbalance. z
CHECK the water pump for
excessive end play.
INSPECT the water pump
with the drive belt off for
imbalance. INSTALL a new
water pump as necessary.
REFER to Section 303 -
03A .
z Generator has
excessive end play. z
CHECK the generator for
excessive end play.
REPAIR or INSTALL a new
generator. REFER to
Section 414 - 02 .
z Pinging noise zExhaust system leak. zINSPECT the exhaust
system for leaks. REPAIR
as necessary.
z Gasoline octane too
low. z
VERIFY with customer the
type of gasoline used.
CORRECT as necessary.
z Knock sensor
operation. z
CHECK the knock sensor.
INSTALL a new knock
sensor as necessary.
REFER to Section 303 - 14 .
z Incorrect spark
timing. z
CHECK the spark timing.
REPAIR as necessary.
z High operating
temperature. z
INSPECT cooling system
for leaks. CHECK the
coolant level. REFILL as
necessary. CHECK the
coolant for the correct mix
ratio. DRAIN and REFILL
as needed. CHECK engine
operating temperature is
within specifications.
REPAIR as necessary.
z Foul- out spark plug. zCHECK the spark plugs.
REPAIR or INSTALL new
spark plugs as necessary.
z Catalytic converter. zAcceptable noise.
z Knocking noise—
light knocking
noise, also z
Excessive clearance
between the piston
and the cylinder wall. z
Engine cold and at high
idle. Using an EngineEAR,
pull a spark plug or fuel Klj . 24 ba
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Pinpoint Tests
The pinpoint tests are a step-by-
step diagnostic process designed to determine the cause of a z
Bump—occurs
when shifting
from PARK to
a drive or
reverse
position.
Similar to
Clunk but with
no sound z
Initial gear
engagement. z
Acceptable condition.
z Buzz or hiss zIncorrect driveline
angles. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to Section 205 - 00 .
z Worn or damaged
main control
solenoids or valves. z
Using a transmission tester,
ACTIVATE the solenoids to
duplicate sound. INSTALL
new components as
necessary. REFER to Section 307 - 01 .
z Vibration— a
high frequency
(20–80 Hz) that
is felt through
the seat or
gear shifter.
Changes with
engine speed z
Transmission cooler
lines grounded out. z
CHECK the transmission
cooler lines. REPAIR as
necessary.
z Flexplate to torque
converter nuts loose. z
CHECK the flexplate nuts.
TIGHTEN to specification.
REFER to Section 307 - 01 .
z Fluid filler tube
grounded out. z
CHECK the fluid filler tube.
REPAIR as necessary.
z Shift cable incorrectly
routed, grounded out
or loose. z
CHECK the shift cable.
REPAIR as necessary.
Section 307 - 05 .
z Shutter or
chatter—
occurs with
light to medium
acceleration
from low
speeds or a
stop z
Electrical
inputs/outputs.
z Vehicle wiring
harness.
z Incorrect
inputs/outputs from
the powertrain control
module (PCM), digital
transmission range
(TR) sensor, brake
pedal position (BPP)
sensor, throttle
position (TP) sensor,
transmission speed
sensor (TSS), output
speed shaft (OSS)
sensor or the torque
converter clutch
(TCC). z
CARRY OUT a Torque
Converter Clutch Operation
Test. RUN on- board
diagnostics or self- test.
REFER to Section 307 - 01 .
CLEAR the DTC's, ROAD
TEST and RERUN on- board
diagnostics or self- test. Klj . 47 ba
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6. For vehicles with a two-
piece hub and brake disc assembly:
z Match-mark before disassembly.
z Remove the brake disc.
z Clean the hub and brake disc mounting surfaces with metal surface cleaner.
z Using a die grinder with a mild abrasive (Scotch Brite® type), remove any rust or
corrosion from the hub and brake disc mounting surfaces.
z Align the match- marks and reinstall the brake disc on the hub.
7. CAUTION: Do not use a bench lathe to machine brake discs.
NOTE: The depth of cut must be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter
cuts will cause heat and wear. Heavier cuts will cause poor brake disc surface finish.
Using an on- car brake lathe, machine the brake discs. Follow the manufacturer's instructions.
After machining, make sure the brake disc still meets the thickness specification.
8. Using the special tools, verify that the brake disc lateral runout is now within specification. For additional information, refer to Section 206 - 00 .
9. Remove the special tool hub adapter.
10. Remove any remaining metal chips from the machining operation.
11. For vehicles with a two- piece hub and brake disc assembly:
z Remove the brake disc from the hub.
z Remove any remaining metal chips from hub and brake disc mounting surfaces and from
the ABS sensor.
z Apply a liberal amount of lubricant to the hub flange, pilot area and to the brake disc- to-
hub mounting surface.
z Using the match marks, mount the brake disc on the hub.
12. Install the brake caliper anchor plate and the brake caliper.
13. Install the tire and wheel assembly.
14. Test the system for normal operation. Klj . 2 ba
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SPECIFICATIONS
SECTION 204-
01: Front Suspension 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft lb-
in Front shock absorber upper nut 100 74 —
Front shock absorber-
to-spindle nuts 200 148 —
Shock absorber upper mount-
to-body nuts 40 30 —
Shock absorber upper mount-
to-body bolt 40 30 —
Wheel hub and bearing retainer nut 350 258 —
Stabilizer bar bracket nuts 70 52 —
Stabilizer bar link nuts 19 14 —
Anti-
lock brake sensor bolt 6 — 53
Anti-
lock brake sensor wire bracket nut 28 21 —
Ball joint-
to-front wheel spindle nut 175 129 —
Front suspension lower arm-
to-body nuts 200 148 —
Tie-
rod- to-spindle nuts 55 41 —
Steering gear-
to-crossmember nuts 70 52 —
Wheel nuts 129 95 — Klj . 1 ba
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REMOVAL AND INSTALLATION
Spindle
Removal
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with
the same part number or an equivalent part must be installed, if installation is necessary. Do
not use a part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to ensure correct retention of these parts.
1. Raise the vehicle on a hoist. For additional information, refer to Section 100 - 02 .
2. Remove the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
3. Remove the front wheel hub (1104). For additional information, refer to Wheel Hub and Bearing in this section.
4. Remove the bolt and the ABS sensor.
5. Unclip the ABS sensor wire from the bracket.
SECTION 204-
01: Front Suspension 2003 Mustang Workshop Manual Special Tool(s)
Tie-
Rod End Remover
211- 001 (TOOL- 3290-D) or
Equivalent Klj . 1 ba
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10. Support the front suspension lower arm with a jack stand.
11. Remove the nut and the ABS sensor wire bracket.
12.
WARNING: All vehicles are equipped with gas pressurized shock absorbers which
will extend unassisted. Do not apply heat or flame to the shock absorbers during
removal or component servicing. Failure to follow these instructions can result in
personal injury.
Disconnect the front shock absorber (18124) from the spindle. 1. Remove and discard the nuts and bolts.
2. Disconnect the shock absorber.
13. Remove the spindle. 1. Remove and discard the nut.
2. Remove the spindle. Klj . 3 ba
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REMOVAL AND INSTALLATION
Shock Absorber
Removal
WARNING: All vehicles are equipped with gas pressurized shock absorbers which will
extend unassisted. Do not apply heat or flame to the shock absorbers during removal or
component servicing. Failure to follow these instructions can result in personal injury.
CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with
the same part number or an equivalent part must be installed, if installation is necessary. Do
not use a part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to ensure proper retention of these parts.
1. Raise the vehicle on a hoist. For additional information, refer to Section 100 - 02 .
2. Remove the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
3. Remove the front brake disc. For additional information, refer to Section 206 - 03 .
4. Remove the bolt and the ABS sensor.
5. Unclip the ABS sensor wire from the bracket.
6. Remove the nut and the ABS sensor wire bracket.
SECTION 204-
01: Front Suspension 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 204-
02: Rear Suspension 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft lb-
in Mustang
Rear shock absorber (upper attachment) 40 30 —
Rear shock absorber (lower attachment) 80 59 —
Shock absorber clevis bracket-to-
axle nut 108 80 —
Upper arm-
to-frame bolt 97 72 —
Upper arm-
to-axle bolt 111 82 —
Lower arm-
to-body attachment bolt 150 111 —
Lower arm-
to-axle bolt 150 111 —
Stabilizer bar-
to-lower arm bolt 55 41 —
Parking brake cable bracket 55 41 —
Axle damper front bolt 90 66 —
Axle damper rear nut 90 66 —
Axle damper bracket-
to-frame bolt 80 59 —
Pinion bumper mount-
to-body bolts 14 10 —
Bracket assembly-
to-differential housing bolt 48 35 —
Wheel nuts 129 95 —
Cobra
Subframe-to-
body bolts 103 76 —
Subframe-to-
rear bracket bolts 103 76 —
Subframe rear bracket-
to-body bolts 80 59 —
Shock absorber-
to-lower arm and bushing bolts 133 98 —
Shock absorber-
to-body nuts 40 30 —
Upper arm and bushing-
to-subframe nuts 90 66 —
Upper arm and bushing-
to-knuckle nut 90 66 —
Lower arm and bushing-
to-subframe bolts 250 184 —
Lower arm and bushing-
to-knuckle nut 115 85 —
Toe link-
to-subframe nut 48 35 —
Toe link-
to-knuckle nut 48 35 —
Stabilizer bar bracket bolt 55 41 —
Stabilizer bar link nuts 48 35 —
Rear axle differential rear insulator-
to-axle housing bolts 103 76 —
Rear brake disc dust shield-
to-knuckle bolts 10 — 89
Brake line-
to-rear brake caliper bolt 40 30 —
Parking brake cable bracket-
to-lower arm and bushing bolt 15 11 —
ABS sensor bolt 23 17 — Klj . 1 ba
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