Ford 2003 Mustang Workshop Manual Download

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Main bearing journal maximum taper

0.008 mm (0.0003 in) per 25 mm (1.0 in)

Main bearing journal maximum out-of-round

0.008 mm (0.0003 in) max. in 45 degrees, 0.015

mm (0.006 in) total

Main bearing journal-to-cylinder block clearance
— desired

0.025-0.035 mm (0.001-0.0014 in)

Main bearing journal-to-cylinder block clearance
— allowable

0.013-0.058 mm (0.0005-0.0023 in)

Connecting rod journal diameter

58.682-58.702 mm (2.3103-2.3111 in)

Connecting rod journal maximum taper

0.008 mm per 25 mm (0.0003 in per in)

Connecting rod journal maximum out-of-round

0.008 mm (0.0003 in) max. in 45 degrees, 0.015

mm (0.0006 in) total

Crankshaft maximum end play

0.10-020 mm (0.004-0.008 in)

Piston and Connecting Rod

Piston diameter — code red

96.795-96.782 mm (3.8108-3.8103 in)

Piston diameter — code blue

96.808-96.795 mm (3.8113-3.8108 in)

Piston diameter — code yellow

96.821-96.808 mm (3.8118-3.8113 in)

Piston-to-cylinder bore clearance (undercoated
clearance)

0.018-0.044 mm (0.0007-0.0017 in)

Piston ring end gap — compression (top, in
gauge)

0.17-0.33 mm (0.0067-0.013 in)

Piston ring end gap — compression (bottom, in
gauge)

0.3-0.55 mm (0.0118-0.0217 in)

Piston ring end gap — oil ring (steel rail, in
gauge)

0.15-0.65 mm (0.0059-0.0256 in)

Piston ring groove width — compression (top)

1.54-1.52 mm (0.0606-0.0598 in)

Piston ring groove width — compression
(bottom)

1.54-1.52 mm (0.0606-0.0598 in)

Piston ring groove width — compression (oil)

3.05-3.03 mm (0.1200-0.1193 in)

Piston ring width — compression (top and
bottom)

1.460-1.490 mm (0.0575-0.0587 in)

Piston ring width — compression (oil)

Side seal — snug fit

Piston ring-to-groove clearance (1st and 2nd
ring)

0.030-0.080 mm (0.0012-0.0032 in)

Piston pin bore diameter

22.94-22.98 mm (0.9032-0.9047 in)

Piston pin diameter

23.000-23.003 mm (0.9055-0.9056 in)

Piston pin length

63.55-63.05 mm (2.5096-2.4823 in)

Piston pin-to-piston fit

0.011-0.018 mm (0.0004-0.0007 in)

Piston-to-connecting rod clearance

—

Connecting rod-to-pin clearance

Press fit 8 kilonewtons (1,800 lbs)

Connecting rod pin bore diameter

—

Connecting rod length (center-to-center)

154.66-154.74 mm (6.0890-6.0921 in)

Connecting rod maximum allowed bend

0.04 per 25 mm (0.0016 per in)

Connecting rod maximum allowed twist

0.059 per 25 mm (0.002 per in)

Connecting rod bearing bore diameter

61.635-61.655 mm (2.4266-2.4274 in)

Connecting rod bearing-to-crankshaft clearance

0.025-0.035 mm (0.001-0.0014 in)

. 3

2003 Mustang Workshop Manual

17.11.2011

file:///C:/Ford/2000-2004/tsocache/SHEF_4464/S3B~us~en~...

Summary of Contents for 2003 Mustang

Page 1: ...ic code The VIN is stamped on a metal tab riveted to the instrument panel top upper left of the dash The VIN number is also found on the vehicle certification VC label SECTION 100 01 Identification Codes 2003 Mustang Workshop Manual Item Description 1 World manufacturer identifier WMI 2 Restraint type code 3 Line series body type passenger car 4 Engine code ...

Page 2: ...acturer identifier WMI 1FA Ford USA passenger car Restraint Type Code The fourth VIN position is the vehicle restraint system type code F Active safety belts all positions driver and front passenger air bags Line Series and Body Type Code 5 Computer generated VIN check digit 6 Model year code 7 Assembly plant code 8 Production sequence number ...

Page 3: ...onvertible P45 Two door convertible GT P48 Two door coupe Cobra P49 Two door convertible Cobra Engine Code The eighth VIN position is the engine displacement and number of cylinders code 4 3 8L OHV EFI six cylinder R 4 6L DOHC EFI eight cylinder Mach One X 4 6L SOHC EFI eight cylinder Y 4 6L DOHC S C EFI eight cylinder Cobra Computer Generated Check Digit ...

Page 4: ...assigned computer generated check digit code 0 9 Model Year Code The tenth VIN position is the model year code 3 2003 Assembly Plant Code The eleventh VIN position is the assembly plant code F Dearborn Michigan USA Production Sequence Number ...

Page 5: ...99999 Vehicle Certification VC Label Vehicle Certification VC Label Locator The upper portion of the vehicle certification VC label contains the manufacturer name the month and year of manufacture the certification statement and the VIN It also includes gross vehicle weight ratings GVWR The VC label is located on the left hand door jamb ...

Page 6: ...code 2 Region code 3 Special order code DSO domestic special order FSO foreign special order PTO paint tire option special order 4 Brake type code 5 Interior trim code 6 Tape paint stripe code 7 Radio type code 8 Axle ratio code 9 Transmission code 10 Spring code 11 Powertrain calibration code ...

Page 7: ...ody color B7 Zinc Yellow clear coat CX Dark Shadow Gray Metallic D3 Colorado Red clear coat G2 Redfire water based clear coat L2 True Blue water based clear coat L5 Azure Blue water based clear coat Mach One only SN Sonic Blue water based clear coat SU Amazon Green water based clear coat UA Ebony clear coat YN Silver Metallic water based clear coat Z1 Oxford White clear coat Brake Codes ...

Page 8: ...The brake type codes are 2 Four wheel disc with anti lock brake system ABS 3 Traction control 5 Four wheel disc with anti lock brake system ABS and traction control Interior Trim Codes ...

Page 9: ...T Lea cloth with vinyl base coupe convertible U Shadow Twill cloth GT X Lea cloth with vinyl GT The interior trim colors are 2 Medium Graphite 2 Medium Graphite Midnight Black Cobra H Medium Parchment H Midnight Black Medium Parchment Cobra R Midnight Black Colorado Red Cobra W Midnight Black Z Oxford White Tape Paint Stripe Codes P White Gray tape applique emblem X Black hood and body tape stripe...

Page 10: ...ium electronic AM FM stereo with compact disc CD player and clock 9 CDX6 AM FM stereo with 6 disc compact disc CD changer and MACH 460 subwoofer sound system Z AM FM stereo dual media MP3 with compact disc CD player Axle Ratio Codes ...

Page 11: ...ch One 3 55 ratio LE 4 6L VX 3 27 ratio TE 3 55 locker with independent rear suspension Cobra Transmission Codes The transmission code is 5 Five speed manual T5OD TR3150 base B Six speed manual T56 Cobra K Five speed manual TR3650 GT U Four speed automatic AODE 4R70W Spring Codes ...

Page 12: ...tifies both the front and rear springs The first letter number indicates the front spring code The second letter number indicates the rear spring code Front springs base part number 5310 RH LH Rear springs base part number 5560 RH LH Powertrain Calibration Information ...

Page 13: ...hese protocols are designed to provide worldwide standardization for vehicle calibration If the electronic calibration strategy has been used since 1998 and carried into the current model year protocol 1 will be used Refer to Protocol 1 below If the electronic calibration strategy has been used since 1999 and is carried into the current model year protocol 2 will be used Refer to Protocol 2 below ...

Page 14: ...iate tires drive configurations final drive ratios and other calibration significant factors 5 Design level design level assigned to the engine Item Description 1 Model year model year in which calibration strategy was first introduced 2 Vehicle code 3 Transmission code 4 Unique calibration designates different hardware to similar vehicles Example tires drive ratios etc 5 Fleet code describes flee...

Page 15: ... S California standard includes U S green states C Canada D China E European Community Austria Belgium Denmark Finland France Germany Greece Ireland Italy Luxembourg Netherlands Portugal Spain Sweden and United Kingdom F Extended European Community E plus Croatia Czech Republic Estonia Hungary Norway Poland Romania Russian Federation Slovakia Slovenia Switzerland and Yugoslavia G Gulf Cooperative ...

Page 16: ...els 01 04 Preliminary levels 00 Job 1 production initial certification 05 09 Pre job 1 revisions to calibrations 10 89 Post job 1 revisions to calibrations 0B Durability test level BD On board diagnostics OBD intermediate level pre 05 ...

Page 17: ...upplied 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 vehic...

Page 18: ...To lift the rear or either side of the rear end position the floor jack under the rear lift points ...

Page 19: ...r 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 fla...

Page 20: ...e 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 ...

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Page 22: ...l be required The special operating conditions are towing or carrying heavy loads extensive idling and or driving at low speeds for long distances driving in dusty conditions off road operation There are also exceptions to the Normal Operating Schedule which will require more frequent maintenance for some components Those exceptions are natural gas and propane vehicles fuel tank intervals normal v...

Page 23: ...utomatic transmission fluid every 48 000 km 30 000 miles Change transfer case fluid every 96 000 km 60 000 miles Install a new engine air filter as required Install a new cabin air filter as required When operating in off road conditions Change automatic transmission fluid every 48 000 km 30 000 miles Change transfer case fluid every 96 000 km 60 000 miles Install a new cabin air filter as require...

Page 24: ...locks Inspect for correct operation Lubricate door rubber weatherstrips Inspect for excessive wear Clean body and door drain holes Inspect for clogs and obstructions Special Checks Mustang Only Carry out the following check every 8 000 km 5 000 miles Adjust clutch by lifting pedal manual transmission Mustang only as described in owner guide Normal Schedule The following checks or procedures should...

Page 25: ...ooling system and hoses Inspect exhaust system and heat shields Inspect steering linkage suspension and if equipped driveshaft and ball joints Rotate tires and inspect for wear Install a new engine air filter Install a new fuel filter See ADDITIONAL INFORMATION below If equipped install a new cabin air filter Change automatic transmission transaxle fluid on all vehicles equipped with AX4S 4F50N 4R...

Page 26: ... 000 Miles Change engine oil and install a new oil filter Inspect tires for wear Rotation recommended for optimal tire life Drain coalescent fuel filter and replace filter NGV 88 000 Km 55 000 Miles Change engine oil and install a new oil filter Inspect tires for wear Rotation recommended for optimal tire life 96 000 Km 60 000 Miles Change engine oil and install a new oil filter Inspect brake pads...

Page 27: ...nd install a new oil filter Inspect tires for wear Rotation recommended for optimal tire life 120 000 Km 75 000 Miles Change engine oil and install a new oil filter Inspect automatic transmission fluid level using dipstick Inspect brake pads shoes rotors drums brake lines hoses and parking brake system Inspect wheel ends for end play and noise Inspect engine cooling system and hoses Inspect steeri...

Page 28: ...oil and install a new oil filter Inspect tires for wear Rotation recommended for optimal tire life 160 000 Km 100 000 Miles Change engine oil and install a new oil filter Inspect accessory drive belt s Rotate tires and inspect for wear Install new spark plugs If filled with yellow coolant change coolant or at 5 years whichever comes first Install a new PCV on all cars and light trucks under 6 000 ...

Page 29: ...new PCV valve on all cars and light trucks over 6 000 Gross Vehicle Weight Change automatic transmission transaxle fluid on all vehicles equipped with AX4S 4F50N 4R100 4F27E Inspect automatic transmission fluid level using dipstick on all other vehicles if equipped Install a new camshaft belt on all 2 0L 4 cylinder engines Escort Focus ZX2 and Escape If equipped install new climate controlled seat...

Page 30: ...elds Inspect steering linkage suspension and if equipped driveshaft and ball joints Rotate tires and inspect for wear Install a new engine air filter Install a new fuel filter See ADDITIONAL INFORMATION below If equipped install a new cabin air filter If filled with yellow engine coolant change coolant or at 8 years whichever comes first Change automatic transmission transaxle fluid and filter Cha...

Page 31: ...lubricants should be replaced every 4 800 km 3 000 miles or three months whichever occurs first during extended trailer tow operation above 21 C 70 F ambient and wide open throttle for extended periods above 45 mph The 3 000 mile lube change interval may be waived if the axle was filled with 75W140 synthetic gear lubricant meeting Ford specification WSL M2C192 A part number F1TZ 19B546 B or equiva...

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Page 33: ...ounds are normal for the vehicle type For example Traction Lok differentials produce a slight noise on slow turns after extended highway driving This is acceptable and has no detrimental effect on the locking axle function As a technician it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis For example if the vehicle has automatic o...

Page 34: ... a low amplitude Backlash Gear teeth clearance Boom Low frequency or low pitched noise often accompanied by a vibration Also refer to Drumming Bound Up An overstressed isolation rubber mount that transmits vibration noise instead of absorbing it Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear Buffet Buffeting S...

Page 35: ...relation to the true vertical as measured looking from the side of the vehicle Chatter A pronounced series of rapidly repeating rattling or clicking sounds Chirp A short duration high pitched noise associated with a slipping drive belt Chuckle A repetitious low pitched sound A loud chuckle is usually described as a knock Click A sharp brief non resonant sound similar to actuating a ball point pen ...

Page 36: ...while at cruise Constant Velocity CV Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made Coupling Shaft The shaft between the transfer case and the front drive axle or in a two piece rear driveshaft the front section CPS Cyc...

Page 37: ...t shaft pinion shaft In a two piece driveshaft it is the rearmost shaft Drivetrain All power transmitting components from the engine to the wheels includes the clutch or torque converter the transmission the transfer case the driveshaft and the front or rear drive axle Drivetrain Damper A weight attached to the engine the transmission the transfer case or the axle It is tuned by weight and placeme...

Page 38: ...d increases It is caused by non equal distribution of mass in the rotating or reciprocating components Flexible Coupling A flexible joint Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed Flutter Mid to high 100 2000 Hz intermittent sound due to air flow Similar to a flag flapping in the wind Frequency The rate ...

Page 39: ...ibels The higher the sound s amplitude the higher the intensity and vice versa Isolate To separate the influence of one component to another Knock A heavy loud repetitious sound like a knock on the door Moan A constant low frequency 100 200 Hz tone Also described as a hum Neutral Engine Run Up NERU Test The operation of the engine through the normal rpm range with the vehicle standing still and th...

Page 40: ...s in the plane of rotation lateral is at 90 degrees to the plane of rotation Rattle A random and momentary or short duration noise Ring Gear The large circular driven gear in a ring and pinion gearset Road Test The operation of the vehicle under conditions intended to produce the concern under investigation Roughness A medium frequency vibration A slightly higher frequency 20 to 50 Hz than a shake...

Page 41: ...waddle Shudder A low frequency vibration that is felt through the steering wheel or seat during light brake application Slap A resonance from flat surfaces such as safety belt webbing or door trim panels Slip Yoke Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates Squeak A high pitched transient sound similar to...

Page 42: ...ariations in the construction of the tire that is noticeable when the tire rotates against the pavement This condition can be present on perfectly round tires because of variations in the inner tire construction This condition can occur at wheel rotation frequency or twice rotation frequency Transient A noise or vibration that is momentary a short duration Two Plane Balance Radial and lateral bala...

Page 43: ...s 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 m...

Page 44: ... 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 ...

Page 45: ...ials PVC soft foam tape Urethane hard foam tape Flocked black fuzzy tape UHMW frosted tape Squeak and rattle oil tube Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface These tests are usually done when a suspected air leak noise appears to originate from the seal area or during the align...

Page 46: ...r paper after the door is closed and check the amount of pressure on the weatherstrip There should be a medium amount of resistance as it is withdrawn Continue around the entire seal area If there is little or no resistance this indicates insufficient contact to form a good seal At these points the door the glass or the weatherstrip is out of alignment ...

Page 47: ......

Page 48: ...ion reported on the Write up Job Aid as well as data from the testing to be carried out To begin a successful diagnosis fill out the NVH Diagnostic Guide record the reported findings then proceed to each of the numbered process steps to complete the diagnosis SECTION 100 04 Noise Vibration and Harshness 2003 Mustang Workshop Manual Special Tool s ChassisEAR 107 R2102 or equivalent Electronic Vibra...

Page 49: ......

Page 50: ......

Page 51: ...drive with the customer There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences It is important that the concern is correctly interpreted and the customer descriptions are recorded During the interview ask the following questions When was it first noticed Did it appear suddenly or gradually ...

Page 52: ... the road test on a quiet street where it is safe to duplicate the vibration noise The ideal testing route is an open low traffic area where it is possible to operate the vehicle at the speed in which the condition occurs If possible lower the radio antenna in order to minimize turbulence Identify anything that could potentially make noise or be a source of wind noise Inspect the vehicle for add o...

Page 53: ... Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface The Engine Run Up Tests consist of the Neutral Run Up Test and the Engine Load Test These tests help to determine if the concern is engine speed related The Neutral Run Up Test is used as a follow up test to the Downshift Speed Test when the concern occurs at idle The Engine Load Test helps to identi...

Page 54: ...the tires wheels brakes and the suspension components as sources If necessary repeat this test using other gears and NEUTRAL to verify the results Proceed as necessary Steering Input Test To carry out this test proceed as follows Drive at the speed where the concern occurs while making sweeping turns in both directions If the concern goes away or gets worse the wheel bearings hubs U joints contain...

Page 55: ...e brake or injury to personnel can result CAUTION Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result Block the front and rear wheels Apply the parking brake and the service brake Install a tachometer Shift the transmission into DRIVE and increase and decrease the engine rpm between an idle to approximately 2000 rpm Note the engine...

Page 56: ...ABS and air suspension system noises Start the engine CAUTION Never probe moving parts Isolate the vibration noise by carefully listening Move around the vehicle while listening to find the general location of the vibration noise Then search for a more precise location by using a stethoscope or EngineEAR GO to Symptom Chart Idle Noise Vibration to assist with the diagnosis 6 Check OASIS TSBs Repai...

Page 57: ...oning GO to Symptom Chart Squeak and Rattle 2 While cranking 1 Grinding or whine differential ring gear or starter motor pinion noise GO to Symptom Chart Engine Noise Vibration 2 Rattle Exhaust hanger exhaust heat shield or A C line noise GO to Symptom Chart Squeak and Rattle 3 Vibration Acceptable condition 3 At idle Idle noise GO to Symptom Chart Idle Noise Vibration Idle vibration or shake GO t...

Page 58: ...veline shudder GO to Symptom Chart Driveline Noise Vibration Engine vibration GO to Symptom Chart Engine Noise Vibration 3 Turning noise GO to Symptom Chart Steering Noise Vibration 4 Braking Clicking sound is signaling ABS is active Acceptable ABS sound A continuous grinding squeal GO to Symptom Chart Brake Noise Vibration Brake vibration shudder GO to Symptom Chart Brake Noise Vibration 5 Clutch...

Page 59: ...seal Door misaligned REALIGN the door CHECK door gaps and fit in the door opening and ADJUST as necessary Scuff plate installed incorrectly REINSTALL the scuff plate Seal or seal push pins damaged INSTALL a new seal Air leak around glass run Door glass misaligned ADJUST the door glass Glass run installed incorrectly ADJUST the glass run INSERT foam in the glass run carrier Leak path behind glass r...

Page 60: ...misaligned damaged REALIGN or INSTALL a new seal as necessary Wind noise from side view mirror Outside mirror housing misaligned REALIGN with the edges shingled correctly and no gaps Mirror sail gasket folded misaligned REINSTALL with the gasket unfolded and aligned correctly Mirror housing trim cap installed incorrectly REINSTALL with the edges shingled to the air flow Air leak through mirror hou...

Page 61: ...seal Air leak around the liftgate flip window perimeter Loose fit seal PINCH the seal carrier to improve the retention to the seal flange Seal misaligned REINSTALL the seal Glass misaligned REALIGN the glass Seal damaged INSTALL a new seal Wind noise from antenna Shape of antenna INSTALL an antenna boot or a spiral antenna Air leak around antenna cable access hole INSPECT the antenna access hole g...

Page 62: ...al with foam to reshape it Gap between side rail and header seal at A pillar ADJUST the J hook vinyl top Air leak at rear quarter glass division bar vehicles with a convertible top No contact between front side glass and quarter glass division bar ADJUST the front side glass regulator and the rear quarter glass regulator Air leak or wind noise from top of side glass vehicles with a convertible top...

Page 63: ...cation and shape REMOVE per customer direction if it is a dealer installed option Symptom Chart Brake Noise Vibration Condition Possible Sources Action Rattling noise Caliper mounting bolts loose CHECK the caliper bolts TIGHTEN to specifications REFER to Section 206 03 for front disc brakes or Section 206 04 for rear disc brakes Damaged or worn caliper pins or retainers CHECK the caliper pins and ...

Page 64: ...ont disc brakes and Section 206 04 for rear disc brakes Moaning noise Brake linings contaminated with grease or oil INSPECT the brake pads and shoes for contamination REPAIR or INSTALL new components as necessary REFER to Section 206 03 for front disc brakes or Section 206 04 for rear disc brakes Brake vibration shudder occurs when brakes are applied Uneven disc or drum wear Uneven disc brake pad ...

Page 65: ...tial side gears and pinion gears DISASSEMBLE the differential carrier INSPECT the side and pinion gears for abnormal wear patterns or broken teeth INSTALL new gears as necessary REFER to Section 205 02A for Ford 7 5 rear axles or Section 205 02B for Ford 8 8 integral axles Driveline clunk loud clunk when shifting from reverse to drive Incorrect axle lubricant level CHECK the lubricant level FILL t...

Page 66: ...ring acceleration or from cruise to coast deceleration Damaged or worn inboard constant velocity CV joint INSPECT the inboard CV joint and boot REPAIR or INSTALL a new CV joint as necessary Driveline clunk 4WD vehicles occurs during shift on the fly engagement Clutch relay Shift motor Transfer case GEM CHECK the 4WD engagement system REPAIR or INSTALL new components as necessary Clicking popping o...

Page 67: ...n 205 02A for Ford 7 5 rear axles or Section 205 02B for Ford 8 8 integral axles Buzz buzzing noise is the same at cruise or coast deceleration Damaged or worn tires CHECK for abnormal tire wear or damage INSTALL a new tire as necessary REFER to Section 204 04 Incorrect driveline angles CHECK for correct driveline angles REPAIR as necessary REFER to Section 205 00 Rumble or boom noise occurs at co...

Page 68: ...ion ADJUST or INSTALL new components as necessary REFER to Section 205 02A for Ford 7 5 rear axles or Section 205 02B for Ford 8 8 integral axles Knock noise occurs at various speeds Not affected by acceleration or deceleration Gear tooth damage to the drive side of the ring and pinion CHECK the differential case and ring and pinion for damage INSTALL new components as necessary REFER to Section 2...

Page 69: ... on the driveshaft slip yoke CLEAN and INSPECT the splines of the slip yoke driveshaft and coupling shaft for a worn damaged or galled condition INSTALL a new slip yoke or driveshaft assembly as necessary REPAIR as necessary REFER to Section 205 01 Driveline vibration occurs at cruising speeds U joints are worn CHECK for wear or incorrect seating INSTALL new U joints as necessary REFER to Section ...

Page 70: ...FER to Section 205 00 Incorrectly seated CV joint in the front wheel hub CHECK the outer CV joint for correct seating into the hub REPAIR as necessary Symptom Chart Engine Noise Vibration Condition Possible Sources Action Grinding noise occurs during engine cranking Incorrect starter motor mounting INSPECT the starter motor for correct mounting REPAIR as necessary REFER to Section 303 06 Starter m...

Page 71: ... end play REPAIR or INSTALL a new generator REFER to Section 414 02 Pinging noise Exhaust system leak INSPECT the exhaust system for leaks REPAIR as necessary Gasoline octane too low VERIFY with customer the type of gasoline used CORRECT as necessary Knock sensor operation CHECK the knock sensor INSTALL a new knock sensor as necessary REFER to Section 303 14 Incorrect spark timing CHECK the spark ...

Page 72: ...rings and the crankshaft Engine warm and at idle Using an EngineEAR PULL a spark plug or fuel injector connector until the noise goes away INSTALL new bearings REFER to Section 303 01A for 3 8L engines or Section 303 01B for 4 6L 2V engines Knocking deep knocking noise Noise is most noticeable when engine is warm at lower rpm and under a light load and then at float Worn or damaged crankshaft main...

Page 73: ...s INSPECT the exhaust system for leaks or damage REPAIR as necessary REFER to Section 309 00 Rattling noise noise from the upper engine valve train Worse when engine is cold Low oil level CHECK oil level FILL as necessary Thin or diluted oil INSPECT the oil for contamination If oil is contaminated CHECK for the source REPAIR as necessary CHANGE the oil and filter Low oil pressure CARRY OUT an oil ...

Page 74: ...ation increases intensity as engine rpm is increased Engine out of balance CARRY OUT Neutral Engine Run Up NERU Test ROTATE the torque converter 120 for 3 bolt and 180 for 4 bolt INSPECT the torque converter pilot outer diameter to crankshaft pilot inner diameter REPAIR as necessary REFER to Section 307 01 Engine vibration is felt with increases and decreases in engine rpm Strain on exhaust mounts...

Page 75: ...LL a new spark plug wire s as necessary Contaminated fuel INSPECT the fuel for contamination DRAIN the fuel system and refill Worn or damaged torque converter CHECK the torque converter INSTALL a new torque converter as necessary REFER to Section 307 01 Symptom Chart Idle Noise Vibration Condition Possible Sources Action Idle air control IAC valve moan occurs on throttle tip out IAC valve is conta...

Page 76: ...m passes the load test the noise is from the generator bearings INSTALL new bearings If the system fails the load test INSTALL a new generator REFER to Section 414 02 Engine driven cooling fan moan occurs during the first start of the day It is most objectionable near idle speeds up to 2000 rpm The noise increases with rpm The viscous cooling fan clutch engages until the fluid in the clutch reache...

Page 77: ...ch or loudness while changing the HVAC system blower speed Damaged or worn HVAC blower bearing INSTALL a new blower motor REFER to Section 412 02 Air conditioning A C clutch ticking occurs when the compressor clutch engages Acceptable noise Incorrect air gap LISTEN to the clutch to determine if the noise occurs with clutch engagement A small amount of noise is acceptable If the noise is excessive ...

Page 78: ...20 80 Hz or buzz that is felt through the steering wheel or seat Exhaust system mounts bound up VERIFY concern occurs at engine firing frequency CHECK that the exhaust system vibrates at the same frequency as the engine ADD 9 14 km 20 30 lb to the tail pipe to test CARRY OUT Exhaust System Neutralizing in this section Body mounts loose INSPECT the body mounts REPAIR as necessary Power steering lin...

Page 79: ...REPAIR as necessary REFER to Section 204 01 Worn or damaged shock absorber strut INSPECT the shock absorber for damage CARRY OUT a bounce test to isolate the noise INSTALL a new shock absorber strut as necessary REFER to Section 204 01 for the front shock absorber strut or Section 204 02 for the rear shock absorber strut Rattle heard when closing opening the door or window Loose internal door mech...

Page 80: ...tom Chart Steering Noise Vibration Condition Possible Sources Action Steering grunt or shudder occurs when turning into or out of a turn at low speeds temperature sensitive Steering gear or power steering hoses GO to Steering Gear Grunt Shudder Test component test in this section Steering System clonk hydraulic knocking sound Air in the steering hydraulic system CHECK for leaks in the system PURGE...

Page 81: ...REFER to Section 211 04 Loose damaged or worn tie rod ends TIGHTEN the nuts to specification or INSTALL new tie rod ends as necessary REFER to Section 211 02 Steering gear insulators or mounting bolts loose or damaged TIGHTEN the bolts or INSTALL new bolts as necessary REFER to Section 211 02 Steering column intermediate shaft bolts are loose TIGHTEN the bolts to specification REFER to Section 211...

Page 82: ...y lubricated column bearings LUBRICATE or INSTALL new steering column bearings as necessary REFER to Section 211 04 Steering shaft insulators damaged or worn INSTALL new insulators REFER to Section 211 04 Intermediate flexible shaft compressed or extended INSPECT the rubber spider coupling for damage INSTALL a new intermediate flexible shaft REFER to Section 211 04 Steering column squeak or cracks...

Page 83: ...211 02 Damaged valve cover O ring seal REPAIR or INSTALL a new power steering pump as necessary REFER to Section 211 02 Power steering pump clicking mechanical noise Power steering pump rotor slippers too long excessive rotor slipper to slot clearance or damaged or worn rotor assembly REPAIR or INSTALL a new power steering pump as necessary REFER to Section 211 02 Power steering pump clatter noise...

Page 84: ...r damaged ball joints CARRY OUT a ball joint inspection INSTALL new ball joints or control arms as necessary Click or snap occurs when accelerating around a corner Damaged or worn outboard CV joint INSPECT the outboard CV joint and boot REPAIR or INSTALL a new CV joint as necessary Front suspension noise a squeak creak or rattle noise Occurs mostly over bumps or rough roads Steering components Loo...

Page 85: ...peeds Abnormal wear patterns SPIN the tire and CHECK for tire wear INSTALL a new tire as necessary INSPECT for damaged worn suspension components CARRY OUT wheel alignment Tire noise noise tone lowers as the vehicle speed is lowered Out of balance tire BALANCE the tire and road test INSTALL a new tire as necessary REFER to Section 204 04 Tire noise ticking noise changes with speed Nail puncture or...

Page 86: ...INSTALL a new tire as necessary REFER to Section 204 04 Worn or damaged wheel studs or elongated stud holes INSPECT the wheel studs and wheels INSTALL new components as necessary REFER to Section 204 01 for the front wheels or Section 204 02 for the rear wheels Excessive lateral runout of the wheel or tire CARRY OUT a lateral runout test of the wheel and tire CHECK the wheel tire and hub REPAIR or...

Page 87: ...gned clutch release bearing INSTALL a new clutch release bearing REFER to Section 308 01 Clutch grating grinding noise occurs when clutch pedal is depressed Clutch pressure plate fingers bent or worn INSPECT the clutch pressure plate release fingers INSTALL a new pressure plate as necessary REFER to Section 308 01 Contact surface of clutch release bearing worn or damaged INSTALL a new clutch relea...

Page 88: ...lywheel runout check INSTALL a new flywheel as necessary REFER to Section 303 01A for 3 8L engines or Section 303 01B for 4 6L 2V engines Clutch chatter noise noise when clutch pedal is released at initial take off Clutch is hard to engage and disengage Pilot bearing worn damaged or not correctly aligned in bore INSPECT the clutch pressure plate release fingers for uneven wear clutch components bu...

Page 89: ...CHECK the reverse idler gear REPAIR as necessary REFER to Section 308 03A for T50D transmissions or Section 308 03B for TR3650 transmissions Rough running engine cylinder misfire CHECK the ignition system CARRY OUT a cylinder power test REFER to Section 303 00 Excessive backlash in gears CHECK the gear backlash ADJUST as necessary REFER to Section 205 02A for Ford 7 5 rear axles or Section 205 02B...

Page 90: ...ssing noise in neutral or in forward gears As bearings wear or break up the noise changes to a thumping noise Damaged or worn bearings INSPECT the transmission bearings INSTALL new bearings as necessary REFER to Section 308 03A for T50D transmissions or Section 308 03B for TR3650 transmissions Transmission knocking thudding noise at low speeds in forward gears Bearings with damaged balls or roller...

Page 91: ...flation pressures are correct Transfer case growl rumble noise at all ranges A small amount of planetary noise can be heard when the transfer case is operated in low range Damaged or worn bearings or planetary gear DISASSEMBLE the transfer case CHECK the bearings or planetary gear for wear or damage REPAIR as necessary Transfer case scraping grating noise at all ranges Excessively stretched drive ...

Page 92: ...e REPAIR or INSTALL new components as necessary REFER to Section 307 01 Whine the pitch changes with engine speed A worn or damaged accessory drive component CARRY OUT the Engine Accessory Test REPAIR or INSTALL new components as necessary Incorrect fluid level CHECK that the transmission is filled to the correct level ADD fluid as necessary REFER to Section 307 01 Partially blocked filter INSPECT...

Page 93: ...rrect band clutch apply pressure CARRY OUT the line pressure tests REPAIR or INSTALL components as necessary REFER to Section 307 01 Worn or damaged torque converter CARRY OUT the torque converter service and replacement check REFER to Section 307 01 Clunk occurs when shifting from PARK to a drive or reverse position Damaged powertrain mounts INSPECT the powertrain mounts for damage INSTALL new mo...

Page 94: ...mission cooler lines REPAIR as necessary Flexplate to torque converter nuts loose CHECK the flexplate nuts TIGHTEN to specification REFER to Section 307 01 Fluid filler tube grounded out CHECK the fluid filler tube REPAIR as necessary Shift cable incorrectly routed grounded out or loose CHECK the shift cable REPAIR as necessary Section 307 05 Shutter or chatter occurs with light to medium accelera...

Page 95: ...FY condition with customer TEST the vehicle for normal operation A3 NORMAL ACTUATION OF THE ABS SYSTEM DIAGNOSIS During moderate to heavy braking noise from the hydraulic control unit HCU and pulsation in the brake pedal can be observed Pedal pulsation coupled with noise during heavy braking or on loose gravel bumps wet or snowy surfaces is acceptable and indicates correct functioning of the ABS s...

Page 96: ... to A8 No Vehicle is OK A8 CHECK THE REAR SUSPENSION Check the rear suspension for Broken or loose bolts Damaged or worn springs or spring bushings Worn or damaged upper and lower control arm bushings Worn or damaged trailing arms Loose or rough rear bearings Uneven tire wear Are all the suspension components in satisfactory condition Yes GO to A9 No REPAIR or INSTALL new components as necessary T...

Page 97: ...R TICKING NOISE Using an EngineEAR listen at the water pump for ticking noise Is the water pump the source of the noise Yes INSTALL a new water pump REFER to Section 303 03A TEST the system for normal operation No GO to B5 B5 CHECK FOR AN OBSTRUCTION OF THE COOLING FAN Inspect the cooling fan for obstructions Check the cooling fan and shroud for wear or damage Was there an obstruction or does the ...

Page 98: ...out the Vehicle Cold Soak Procedure in this section Key in START position Turn the steering wheel while the noise is occurring and listen for changes in sound pitch or loudness Key in OFF position Does the sound pitch or loudness change while turning the steering wheel Yes GO to D2 No CONDUCT a diagnosis on other suspect accessory drive components D2 VERIFY THE SOURCE Key in START position Place a...

Page 99: ... to Take F1 CHECK THE EXHAUST SYSTEM Key in START position Increase the engine rpm until the noise is the loudest Note the engine rpm Key in OFF position Add approximately 9 kg 20 lb of weight to the exhaust system First place the weight at the tail pipe and test then at the front pipe Key in START position Increase the engine rpm and listen for the drumming noise Note the engine rpm if the noise ...

Page 100: ...ineEAR listen closely at the cylinder block by placing a probe on or near each freeze plug Key in OFF position Is the noise source apparent Yes REPAIR or INSTALL new components as necessary No GO to G3 G3 CHECK FOR NOISE WHILE DISCONNECTING EACH FUEL INJECTOR ELECTRICAL CONNECTOR ONE AT A TIME Key in START position Disconnect each fuel injector electrical connector one at a time to decrease piston...

Page 101: ...ruts loose or damaged Yes TIGHTEN to specifications if loose INSTALL new front shock absorbers struts if damaged TEST the system for normal operation No GO to H4 H4 CHECK THE FRONT SPRINGS Check the front spring and front spring mounts brackets for wear or damage Are the front springs or spring mounts brackets worn or damaged Yes REPAIR or INSTALL new components as necessary TEST the system for no...

Page 102: ...IGHTEN to specifications if loose INSTALL new rear shock absorbers struts if damaged TEST the system for normal operation No GO to I3 I3 CHECK THE REAR SPRINGS Check the rear springs and rear spring mounts brackets for wear or damage Are the rear springs or spring mounts brackets worn or damaged Yes REPAIR or INSTALL new components as necessary TEST the system for normal operation No GO to I4 I4 C...

Page 103: ...er suspect systems J2 CHECK THE FRONT WHEEL BEARINGS Check the front wheel bearings Refer to Wheel Bearing Check in this section Are the wheel bearings OK Yes GO to J3 No INSPECT the wheel bearings ADJUST or REPAIR as necessary TEST the system for normal operation J3 INSPECT THE TIRES Check the tires for missing weights Check the wheels for damage Inspect the tire wear pattern Refer to the Tire We...

Page 104: ... CHECK THE HUB BRAKE DISC OR DRUM PILOT RUNOUT OR BOLT CIRCLE RUNOUT Measure the pilot or bolt circle runout A typical specification for radial runout is Pilot runout less than 0 15 mm 0 006 inch Bolt circle runout less than 0 38 mm 0 015 inch Is the radial runout within specifications Yes INSTALL a new wheel TEST the system for normal operation No REPAIR or INSTALL new components as necessary REF...

Page 105: ...ons Yes INSTALL a new wheel TEST the system for normal operation No REPAIR or INSTALL new components as necessary REFER to Section 204 01 for the front wheels or Section 204 02 for the rear wheels Test Step Result Action to Take K1 CHECK FOR FRONT WHEEL BEARING ROUGHNESS Chock the rear wheels Raise and support the front end of the vehicle so that the front wheel and tire assemblies can spin Spin t...

Page 106: ...inpoint Test J Is the runout within specifications Yes BALANCE the front wheel and tire assemblies If any tire cannot be balanced INSTALL a new tire TEST the system for normal operation No GO to K6 K6 MATCH MOUNT THE TIRE AND WHEEL ASSEMBLY Mark the high runout location on the tire and also on the wheel Break the assembly down and rotate the tire 180 degrees halfway around on the wheel Inflate the...

Page 107: ...ROM THE REAR OF THE VEHICLE WARNING If only one drive wheel is allowed to rotate speed must be limited to 55 km h 34 mph using the speedometer reading since actual wheel speed will be twice that indicated on the speedometer Exceeding a speed of 55 km h 34 mph or allowing the drive wheel to hang unsupported can result in tire disintegration or differential failure which can cause serious personal i...

Page 108: ... the chassis Are any mounts or engine components grounded Yes REPAIR as necessary TEST the system for normal operation No GO to L2 L2 CHECK THE ACCESSORY DRIVE Remove the accessory drive belt Does the vibration stop with the accessory drive belt removed Yes DIAGNOSE the accessory drive components No GO to L3 L3 CHECK FOR LOOSE CLUTCH PRESSURE PLATE BOLTS Check for loose clutch pressure plate bolts...

Page 109: ...e air springs which can result in shifting of the vehicle during these operations Inspect the transfer case for loose or missing mounting bolts Check for fluid seepage between the transfer case and the transmission Are the mounting bolts missing or loose Yes TIGHTEN to specifications or INSTALL new bolts as necessary TEST the system for normal operation No GO to M2 M2 INSPECT THE REAR DRIVESHAFT N...

Page 110: ...ONLY NOTE Index mark the driveshaft to the pinion flange and to the output shaft before removal Remove the rear driveshaft Plug the transfer case with an output shaft seal plug NOTE Shift the transfer case into 4WD high so the vehicle is driven by the front driveshaft only Test drive the vehicle Is the vibration gone Yes INSTALL and BALANCE the rear driveshaft TEST the system for normal operation ...

Page 111: ...a normal steering system condition 7 If a loud grunt is heard or a strong shudder is felt fill and purge the power steering system Checking Tooth Contact Pattern and Condition of the Ring and Pinion There are two basic types of conditions that will produce ring and pinion noise The first type is a howl or chuckle produced by broken cracked chipped scored or forcibly damaged gear teeth and is usual...

Page 112: ... complete turns in both directions until a good clear tooth pattern is obtained Inspect the contact patterns on the ring gear teeth 7 A good contact pattern should be centered on the tooth It can also be slightly toward the toe There should always be some clearance between the contact pattern and the top of the tooth Tooth contact pattern shown on the drive side of the gear teeth 8 A high thick co...

Page 113: ...Tooth contact pattern shown on the drive side of the gear teeth The drive pinion depth is correct Increase the differential ring gear backlash 10 A contact pattern that is worn in the center of the differential ring gear tooth toward the heel Tooth contact pattern shown on the drive side of the gear teeth The low contact pattern indicates that the drive pinion is installed too deep into the carrie...

Page 114: ...ooth contact pattern shown on the drive side of the gear teeth The pinion gear depth is correct Decrease the differential ring gear backlash Tire Wear Patterns and frequency calculations Tire Wear Chart ...

Page 115: ...rations felt in the steering wheel are related to the front tire and wheel assemblies Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies This can initially isolate a concern to the front or rear Careful attention must be paid to the tire and wheels There are several symptoms that can be caused by damaged or worn tire and wheels Carry out a careful visual inspect...

Page 116: ... vibration with 835 mm 33 in tires 40 10 4 Multiply 4 by 105 420 rpm Divide 420 rpm by 60 seconds 7 Hz at 40 mph Tire Speed and Frequency Chart Tire Diameter Tire RPM Hz Tire RPM Hz Tire RPM Hz Tire RPM Hz mm inch 16 km h 10 mph 80 km h 50 mph 97 km h 60 mph 113 km h 70 mph 483 19 182 910 15 1092 18 1274 21 508 20 173 865 14 1038 17 1211 20 533 21 165 825 14 990 16 1155 19 560 22 158 790 13 948 16...

Page 117: ......

Page 118: ...move the tire and wheel assembly 3 Remove the brake caliper and the brake caliper anchor plate Refer to the appropriate section in Group 206 for the procedure 4 Inspect the brake linings Install new brake linings if below specification For additional information refer to the appropriate brake section 5 Measure and record the brake disc thickness Install a new brake disc if the thickness after mach...

Page 119: ...w 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 hu...

Page 120: ......

Page 121: ...springs which can result in shifting of the vehicle during these operations 1 Raise and support the vehicle 2 Loosen but do not remove the powertrain drivetrain mount fasteners 3 Lower the vehicle 4 CAUTION Do not twist or strain the powertrain drivetrain mounts Move the vehicle in forward and reverse 0 6 1 2 meters 2 4 ft 5 Raise and support the vehicle 6 Tighten the powertrain drivetrain mount f...

Page 122: ...ing temperature as thermal expansion can be the cause of a strain problem Raise and support the vehicle 2 Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight 3 Loosen all exhaust flange joints 4 Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress 5 Tighten the muffler connection 6 Tighten all...

Page 123: ......

Page 124: ...s freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly Spin the tire by hand to check the wheel bearings for roughness 3 Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing 4 If the tire and wheel hub is loose on the spindle does not rotate freely ...

Page 125: ......

Page 126: ...Cobra Caster Camber 0 8 0 2 0 8 0 2 0 0 50 Toe positive value is toe in negative value is toe out 0 20 0 15 General Specifications Item Specification Front Ride Height Front 4 mm 7 6 mm 0 2 in 0 3 in Rear Ride Height Rear GT and Base 128 mm 5 in Rear Cobra 18 mm 7 6 mm 1 4 in 0 3 in Vehicle Lean Side to Side Differences Front maximum 13 mm 0 5 in Rear maximum 13 mm 0 5 in Dogtracking Maximum 13 mm...

Page 127: ...escription Nm lb ft Front suspension camber adjustment plate bolt 40 30 Front suspension camber adjustment plate nuts 40 30 Rear camber adjustment nut 90 66 Toe link jam nuts 55 41 Tie rod jam nuts 55 41 ...

Page 128: ...pindle tie rod 3280 Camber Negative and Positive Camber Camber is the vertical tilt of the wheel 1007 when viewed from the front Camber can be positive or negative and has a direct effect on tire wear Caster Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side Caster specifications in this section will give the vehicle the best directio...

Page 129: ...Toe Positive Toe Toe In Negative Toe Toe Out The vehicle toe setting affects tire wear and directional stability Ride Height Front Ride Height Measurement ...

Page 130: ...Rear Ride Height Measurement GT and Base Item Description 1 Ride height B A 2 Measurement A 3 Measurement B ...

Page 131: ...nder Wander is the tendency of the vehicle to require frequent random left and right steering wheel 3600 corrections to maintain a straight path down a level road Item Description 1 Body reinforcement 2 Ride height shortest distance 3 Rear axle Item Part Number Description 1 Front track 2 Rear track Item Part Number Description 1 Vehicle centerline 2 Axle centerline 3 Thrust angle ...

Page 132: ...on felt in the steering wheel that must be overcome to keep the vehicle going straight Drift describes what a vehicle with this condition does with hands off the steering wheel Drift pull may be induced by conditions external to the vehicle i e wind road camber Poor Groove Feel Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is ro...

Page 133: ......

Page 134: ...rmissible and is a result or correct shock lubrication Weepage is a condition in which a film of oil accumulates on the thin tube body and is normally noticed due to the collection of dust in this area If shock absorbers exhibit this weepage condition they are functional units and new shock absorbers should not be installed Leakage is a condition in which the entire shock absorber body is covered ...

Page 135: ...n components INSPECT the front and rear suspension system REPAIR or INSTALL new suspension components as necessary REFER to Section 204 01 or Section 204 02 Drive axle damaged REPAIR as necessary Refer to the appropriate section in Group 205 for the procedure Drift pull Unequal tire pressure ADJUST tire pressure Excessive side to side difference in caster or camber CHECK the wheel alignment ADJUST...

Page 136: ...01 Front wheel bearing s REFER to Wheel Bearing Inspection in this section Wheel or tire runout REFER to Section 204 04 Tire flatspotting REFER to Section 204 04 Shock absorber s INSTALL new shock absorber s as necessary Loose worn or damaged ball joint s GO to the Ball Joint Inspection component test in this section Loose worn or damaged steering components REFER to Section 211 00 Front wheel ali...

Page 137: ... to Section 204 01 or Section 204 02 Front coil springs or rear springs INSTALL new front coil springs or rear springs as necessary REFER to Section 204 01 or Section 204 02 Incorrect ride height Lateral tilt out of specification CHECK ride height INSTALL new front coil springs or rear springs as necessary REFER to Section 204 01 or Section 204 02 Vibration noise Tire or wheel runout Tire flatspot...

Page 138: ...ed 4 While an assistant pulls and pushes the bottom of the tire observe the relative movement between the lower spindle arm and the front suspension lower arm ball joint Any movement at or exceeding the specification indicates a worn or damaged lower ball joint Install a new front suspension lower arm Refer to Section 204 01 Steering components REFER to Section 211 00 Wheel alignment CHECK wheel a...

Page 139: ......

Page 140: ...ow movement of the tire and wheel assembly Grasp each tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the wheel bearing 3 If the tire and wheel hub is loose on the wheel spindle or does not rotate freely install a new front wheel hub 1104 as necessary For additional information refer to Section 204 01 SECTION 204 00 Suspension System Genera...

Page 141: ...ster split then slotting the shock tower at the front shock absorber 18124 upper mounting point is an acceptable method This procedure should not be routinely performed with all alignments and only after all other possible sources have been inspected and corrected as necessary Determine the amount of caster adjustment needed If no more than 0 6 degree is needed only one shock tower needs to be slo...

Page 142: ...the top of the front shock absorber toward the rear of the vehicle will increase the caster reading for that side Each millimeter of adjustment should yield approximately 0 12 degree of caster change Do not cut slots any longer than 5 mm 0 2 in in any direction Remove any burrs Clean and paint any exposed metal 8 Position the strut and spring assembly Lower the front end 9 Install the front suspen...

Page 143: ...rks and position the front suspension camber adjustment plate at the correct caster setting All vehicles 11 Tighten the nuts and bolt 12 Recheck the wheel alignment Follow the manufacturer s instructions Adjust as necessary ...

Page 144: ......

Page 145: ... and the cam to the correct camber setting 3 Tighten the nut while holding the bolt and the cam stationary 4 Recheck the wheel alignment Follow the manufacturer s instructions Adjust as necessary SECTION 204 00 Suspension System General Information 2003 Mustang Workshop Manual ...

Page 146: ......

Page 147: ...heel to the seat 3 Check the toe settings Follow the manufacturer s instructions 4 Remove the clamps 5 Loosen the nuts Clean and lubricate the nut s and front wheel spindle tie rod threads 6 NOTE Do not allow the steering gear bellows to twist when the front wheel spindle tie rod 3280 is rotated Rotate the front wheel spindle tie rods SECTION 204 00 Suspension System General Information 2003 Musta...

Page 148: ...7 Tighten the nuts 8 Install the clamps 9 Recheck the toe settings Follow the manufacturer s instructions ...

Page 149: ......

Page 150: ...joints hold the tie rod ends while loosening the nuts 2 Rotate the toe link to the correct toe setting 3 Tighten the nuts To prevent damage to the ball joints hold the tie rod ends while tightening the nuts SECTION 204 00 Suspension System General Information 2003 Mustang Workshop Manual ...

Page 151: ...4 Recheck the toe settings Follow the manufacturer s instructions ...

Page 152: ...t 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 cross...

Page 153: ...heel Hub and Bearing in this section 2 Using a press remove the wheel stud 1107 from the wheel hub Installation 1 Using a press install a new wheel stud 2 Install the wheel hub For additional information refer to Wheel Hub and Bearing in this section SECTION 204 01 Front Suspension 2003 Mustang Workshop Manual ...

Page 154: ......

Page 155: ...e 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 and discard the front hub cap grease seal 1N135 5 CAUTION The wheel hub retainer 3B477 is a one time use item and must be replaced with a new reta...

Page 156: ...Installation 1 NOTE Use a new wheel hub retainer and hub cap grease seal To install reverse the removal procedure ...

Page 157: ...e to the protective sleeve with the vehicle in a static level ground position curb height 2 Raise the vehicle on a hoist For additional information refer to Section 100 02 3 Remove the wheel and tire assembly For additional information refer to Section 204 04 4 Remove the front brake disc shield For additional information refer to Section 206 03 5 CAUTION To prevent damage to the front suspension ...

Page 158: ...on refer to Spring in this section 7 Remove the nut and the front suspension lower control arm Discard the nut Installation 1 To install reverse the removal procedure 2 Check wheel alignment Adjust if necessary For additional information refer to Section 204 00 ...

Page 159: ...cified 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 assemblies For additional information refer to Section 204 04 3 Disconnect the front stabilizer bar links 5K483 from the front stabilizer bar 5482 1 Remove the nuts and bushings Discard the nuts 2 Rotate the stabilizer bar...

Page 160: ...er bar Installation 1 NOTE To aid installation coat the necessary parts of the front stabilizer bar and the inside diameter of the stabilizer bar bushing with Rubber Suspension Insulator Lube E25Y 19553 A or equivalent meeting Ford specification ESF M99B112 A To install reverse the removal procedure ...

Page 161: ......

Page 162: ...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 Disconnect the front stabilizer bar links 5K483 from the front stabilizer bar 5482 1 Remove the nuts and bushings Discard the nuts 2 Rotate the stabilizer bar to disconnect the links 3 Remove the stabilizer bar link...

Page 163: ......

Page 164: ...s 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 assemblies For additional information refer to Section 204 04 3 Disconnect the front stabilizer bar links 5K483 from the front stabilizer bar 5482 1 Remove the nuts and bushings Discard the nuts 2 Rotate the stabilize...

Page 165: ...1 NOTE To aid installation coat the necessary parts of the front stabilizer bar and the inside diameter of the stabilizer bar bushing with Rubber Suspension Insulator Lube E25Y 19553 A or equivalent meeting Ford specification ESF M99B112 A To install reverse the removal procedure ...

Page 166: ......

Page 167: ...ues 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 s...

Page 168: ...Using the special tool disconnect the tie rod end from the front wheel spindle 9 CAUTION To prevent damage to the front suspension lower arm 3078 do not remove the nut from the ball joint 3050 at this time Disconnect the ball joint stud from the front wheel spindle 3105 Loosen the ball joint stud two or three turns Sharply rap on the spindle at the ball joint connection to disconnect the ball join...

Page 169: ...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 ...

Page 170: ...Installation 1 To install reverse the removal procedure ...

Page 171: ...2 Check wheel alignment Adjust if necessary For additional information refer to Section 204 00 ...

Page 172: ...e 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 ...

Page 173: ...nsion lower arm and remove the jack stand 10 CAUTION Do not allow the weight of the vehicle to rest on the front brake disc shield Damage to the shield can occur Lower the vehicle to access the upper mount nuts and bolt 11 Remove the shock absorber 1 Remove the bolt and nuts Discard the nuts 2 Remove the shock absorber 12 Position the shock absorber in a vise 13 Remove the nut and the front shock ...

Page 174: ...14 Remove the sleeve and the bushing Installation 1 To install reverse the removal procedure ...

Page 175: ......

Page 176: ......

Page 177: ...d during reassembly to ensure proper retention of these parts 1 Mark the front shock absorber 18124 relative to the protective sleeve with the vehicle in a static level ground position curb height 2 Raise the vehicle on a hoist For additional information refer to Section 100 02 3 Remove the wheel and tire assembly For additional information refer to Section 204 04 4 Remove the cotter pin and nut D...

Page 178: ... the nut and bushing 2 Disconnect the link 7 CAUTION Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur If there is evidence that the intermediate shaft has rotated the clockspring must be removed and recentered For additional information refer to Section 501 20B Remove the bolt and disconnect the intermediate shaft from the ...

Page 179: ...so the front suspension lower arm front bolt can be removed 9 Support the front suspension lower arm with a jack stand inboard of the spring seat 10 NOTE Note position of the front coil spring 5310 in the lower arm spring seat It must be installed in the same position Using the special tool compress the spring until it is loose in the spring insulator 5415 11 Remove the front suspension lower arm ...

Page 180: ...e the spring 1 Swing the front suspension lower arm out of the fender well 2 Remove the spring and the spring insulator Installation 1 Install the spring 1 Position the spring and spring insulator in the front suspension lower control arm 2 Swing the arm into the fender well ...

Page 181: ... NOTE The front suspension lower arm nuts must be tightened with the suspension at curb height Install the bolts and nuts Do not tighten the bolts at this time 4 Make sure the spring is correctly positioned in the front suspension lower arm 1 Spring must not cover this hole 2 Spring must cover this hole 5 Remove the special tool ...

Page 182: ...pension lower arm ball joint and raise the suspension until the shock absorber is compressed to the previously established alignment mark curb height 7 Tighten the nuts 8 Remove the jack stand 9 Install the power rack and pinion steering gear ...

Page 183: ...g 2 Install the nut 12 Connect the tie rod end to the spindle 1 Install the tie rod end into the spindle 2 Install the nut 3 Install a new cotter pin 13 Install the wheel and tire assembly For additional information refer to Section 204 04 14 Lower the vehicle 15 Check wheel alignment Adjust if necessary For additional information refer to Section 204 00 ...

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Page 185: ...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...

Page 186: ...Axle shaft to hub retainer 325 240 Wheel nuts 129 95 ...

Page 187: ... the same part number must be installed if installation becomes necessary If substitution is necessary the part must be of the same finish and property class Torque values must be used as specified during reassembly to make sure of correct retention of these parts The rear suspension consists of the following components rear spring 4460 rear shock absorber 18125 rear upper suspension arm and bushi...

Page 188: ...e vibration damper 3 5A649 Rear lower suspension arm and bushing common LH and RH 4 5560 Rear spring 5 4731 Rear axle bumper bracket 6 4905 Rear axle differential carrier bumper and bracket 7 5A772 Rear stabilizer bar 8 5500 Rear upper suspension arm and bushing common LH and RH ...

Page 189: ...Puller 205 D026 D80L 1013 A or Equivalent Driver 205 199 T83T 3132 A1 Front Hub Remover Replacer 204 069 T81P 1104 C Hub Bearing Remover 204 081 T83P 1104 AH2 Hub Dust Seal Replacer 205 289 T89P 1249 A Rear Hub Remover 205 287 T89P 1225 AH Receiving Cup 205 286 T89P 1104 A Step Plate Adapter 205 D016 D80L 630 5 or Equivalent ...

Page 190: ...class Torque values must be used as specified during reassembly to make sure of correct retention of these parts 1 Remove the rear wheel knuckle 5A968 5A969 For additional information refer to Wheel Knuckle Cobra in this section 2 Remove the bolts and the dust shield Discard the bolts 3 Position the knuckle in a vise 4 NOTE There are two methods for removing the rear hub 1109 from the rear wheel b...

Page 191: ... the press bed supported by the special tool 2 Using the appropriate step plate adapter press the bearing from the knuckle Installation 1 Install the bearing 1 Position the knuckle on the press 2 Using the appropriate step plate adapter press the bearing into the knuckle until the bearing clears the snap ring groove and bottoms out in the bore ...

Page 192: ...llation Failure to follow these instructions can damage the bearing Install the hub 1 Position the knuckle in a press making sure the wheel bearing inner race is supported with the appropriate step plate adapter 2 Using the special tool install the hub 4 Install the dust shield and new bolts ...

Page 193: ...al If necessary install a new dust seal 6 Using a hammer and chisel remove the dust seal 7 Using the special tools install the dust seal 8 Install the knuckle For additional information refer to Wheel Knuckle Cobra in this section ...

Page 194: ......

Page 195: ...100 02 2 Remove the wheel and tire assembly For additional information refer to Section 204 04 3 Remove the rear brake disc For additional information refer to Section 206 04 4 Using the special tool remove and discard the wheel stud Installation CAUTION Do not use air tools to install the wheel stud The serrations in the hub flange can be stripped 1 Install the wheel stud 1 Position a new wheel s...

Page 196: ...nut and washers Discard the nut 3 Install the rear brake disc For additional information refer to Section 206 04 4 Install the wheel and tire assembly For additional information refer to Section 204 04 5 Lower the vehicle ...

Page 197: ...make sure of correct retention of these parts 1 Mark the rear shock absorber 18125 relative to the protective sleeve with the vehicle in a static level ground position curb height 2 Raise the vehicle on a hoist For additional information refer to Section 100 02 3 Support the differential housing with a jack stand 4 Disconnect the upper arm and bushing 5500 from the axle 1 Remove and discard the nu...

Page 198: ...nstall a new nut and bolt Do not tighten at this time 2 Connect the upper arm and bushing to the axle 1 Position the arm and bushing 2 Install a new nut and bolt Do not tighten at this time 3 Raise the suspension until the shock absorber is compressed to the previously established alignment mark curb height ...

Page 199: ...4 Tighten the arm and bushing to mounting bracket bolt 5 Tighten the arm and bushing to axle bolt 6 Lower the suspension and remove the jack stand 7 Lower the vehicle ...

Page 200: ......

Page 201: ...r shock absorber 18125 relative to the protective sleeve with the vehicle in a static level ground position curb height 2 Raise the vehicle on a hoist For additional information refer to Section 100 02 3 Remove both wheel and tire assemblies For additional information refer to Section 204 04 4 Remove the rear brake disc For additional information refer to Section 206 04 5 Remove the rear springs 5...

Page 202: ... Remove and discard the nuts and bolts 2 Remove the upper suspension arm and bushing Installation CAUTION The upper suspension arm and bushing nuts must be tightened with the suspension at curb height Failure to do so can result in bushing failure resulting in poor ride and handling NOTE If installing a new upper suspension arm and bushing mark the cam bolt side of the new arm in the same position...

Page 203: ...ew cam bolt and a new nut Do not tighten the nut at this time 3 Raise the subframe into position and install new front bolts 4 Install the springs For additional information refer to Spring Cobra in this section 5 Position a jack stand under the lower suspension arm and bushing 6 Raise the suspension until the shock absorber is compressed to the alignment mark curb height ...

Page 204: ... remove the jack stand 10 Install the rear brake disc For additional information refer to Section 206 04 11 Install the wheel and tire assembly For additional information refer to Section 204 04 12 Lower the vehicle 13 Check wheel alignment adjust if necessary For additional information refer to Section 204 00 ...

Page 205: ......

Page 206: ...arts 1 Mark the rear shock absorber 18125 relative to the protective sleeve with the vehicle in a static level ground position curb height 2 Remove the muffler assembly ies For additional information refer to Section 309 00 3 Remove the rear spring 5560 For additional information refer to Spring Coil in this section 4 Remove the lower suspension arm and bushing 5A649 from the body attachment 1 Rem...

Page 207: ...dy attachment bolt after installing the spring while the suspension is at curb height Install the rear spring For additional information refer to Spring Coil in this section 3 Install the muffler assembly ies For additional information refer to Section 309 00 ...

Page 208: ...e part must be of the same finish and property class Torque values must be used as specified during reassembly to make sure of correct retention of these parts 1 Raise the vehicle For additional information refer to Section 100 02 2 Disconnect the anti lock brake sensor wires from the brackets 3 Remove the parking brake cable brackets 1 Remove and discard the bolts 2 Remove the parking brake cable...

Page 209: ...ion NOTE Make sure the rear stabilizer bar is not installed upside down A color code is provided on the right passenger side only as an aid for correct positioning NOTE Use new fasteners when installing the stabilizer bar 1 To install reverse the removal procedure ...

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Page 211: ...ssembly to make sure of correct retention of these parts 1 Remove the rear coil springs 5560 For additional information refer to Spring Cobra in this section 2 Raise the subframe into position and remove the front bolts 3 Lower the subframe out of the vehicle 4 NOTE To remove the stabilizer bar link nuts first loosen the nut then use the hex holding feature to prevent the stabilizer bar link ball ...

Page 212: ...r links are of a torque prevailing design New bolts and nuts must be used during installation NOTE To install the stabilizer bar link nuts first install the nuts until snug using the hex holding feature to prevent the stabilizer bar link ball joint from turning Final tighten the nuts using a socket and a torque wrench To install reverse the removal procedure ...

Page 213: ...2 Check wheel alignment Adjust as necessary For additional information refer to Section 204 00 ...

Page 214: ...nal information refer to Section 100 02 2 NOTE Spring is removed for clarity NOTE To remove the nuts first loosen the nut then use the hex holding feature to prevent the stabilizer bar link ball joint from turning while removing the nut Remove the nuts and the stabilizer bar links 5C488 Discard the nuts Installation 1 NOTE The nuts on the stabilizer bar links are of a torque prevailing design New ...

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Page 216: ...t be used as specified during reassembly to make sure of correct retention of these parts 1 Mark the rear shock absorber 18125 relative to the protective sleeve with the vehicle in a static level ground position curb height 2 Raise the vehicle on a hoist For additional information refer to Section 100 02 3 Remove the wheel and tire assembly For additional information refer to Section 204 04 4 Remo...

Page 217: ...isconnect the parking brake cable and conduit from the rear brake caliper 7 Disconnect the parking brake cable and conduit from the knuckle 5A968 5A969 8 Remove the rear brake disc For additional information refer to Section 206 04 9 Support the lower suspension arm and bushing 5A649 with a jack stand ...

Page 218: ...d bolt 11 Remove and discard the cotter pin and nut 12 CAUTION Do not strike the toe link or the knuckle to disconnect the toe link The toe link or the knuckle can be damaged Using the special tool disconnect the toe link 5K899 from the knuckle 13 Mark the cam bolt position relative to the upper suspension arm and bushing 5500 ...

Page 219: ...nnect the upper suspension arm and bushing from the knuckle 1 Remove and discard the nut and bolt 2 Disconnect the arm and bushing from the knuckle 15 Using the special tool press the axle shaft from the hub 1109 16 Remove the knuckle from the lower arm and bushing 1 Remove and discard the nut and bolt 2 Remove the knuckle ...

Page 220: ...the lower suspension arm and bushing 2 Install a new bolt and a new nut Do not tighten the nut at this time 3 Connect the axle shaft to the hub 1 Making sure the splines on the shaft line up with the splines in the hub install the axle shaft into the hub 2 Install a new retainer Do not tighten the retainer at this time 4 Connect the upper suspension arm and bushing to the knuckle 1 Position the up...

Page 221: ...between the lower suspension arm and bushing and the shock absorber Failure to do so can result in damage and failure of the lower suspension arm and bushing Connect the shock absorber to the lower suspension arm and bushing and install the bolt and a new nut 7 Raise the suspension until the shock absorber is compressed to the previously established alignment mark curb height ...

Page 222: ...uspension arm and bushing made during removal are aligned and tighten the nut 10 Lower the suspension and remove the jack stand 11 Install the rear brake disc For additional information refer to Section 206 04 12 Install the parking brake cable and conduit into the knuckle ...

Page 223: ...the ground to make sure of correct bearing seating Failure to do so can cause the retainer to loosen causing extensive vehicle damage and loss of vehicle control Lower the vehicle and apply the parking brake or service brakes 16 Tighten the retainer 17 Install the wheel and tire assembly For additional information refer to Section 204 04 18 Lower the vehicle 19 Check the wheel alignment Adjust as ...

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Page 225: ...sure of 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 rear brake disc For additional information refer to Section 206 04 4 Support the lower suspension arm and bushing 5A649 with a jack stand 5 Remove the nut and bolt and disconne...

Page 226: ...e toe link Discard the bolt and nut Installation 1 CAUTION Make sure the hardened washer is installed between the lower suspension arm and bushing and the shock absorber Failure to do so can result in damage and failure of the lower suspension arm and bushing NOTE The toe link bolt and nuts are of a torque prevailing design A new bolt and new nuts must be installed NOTE Use a new cotter pin To ins...

Page 227: ...2 Check wheel alignment Adjust as necessary For additional information refer to Section 204 00 ...

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Page 229: ...the part must be of the same finish and property class Torque values must be used as specified during reassembly to make sure of correct retention of these parts All vehicles 1 Mark the rear shock absorber 18125 relative to the protective sleeve with the vehicle in a static level ground position curb height 2 Raise the vehicle For additional information refer to Section 100 02 3 Disconnect the ant...

Page 230: ...er Bar in this section All vehicles 6 Support the differential housing with a jack stand 7 Position the special tool 014 00942 under the rear lower suspension arm and bushing to axle pivot bolt 8 Remove and discard the pivot bolt and nut 9 Remove the spring 5560 1 Slowly lower the arm with the special tool 014 00942 2 Remove the rear spring and the rear spring insulators 5536 Installation ...

Page 231: ...ll the lower insulator on the lower arm 3 Install the rear spring Make sure the pigtail on the lower arm is at the rear of the vehicle and pointing toward the left side of the vehicle 4 Install the pivot bolt 1 Carefully raise the lower arm into position with the special tool 014 00942 2 Install a new pivot bolt and nut Do not tighten at this time ...

Page 232: ...rk curb height 7 Tighten the lower arm to axle pivot bolt 8 Lower the rear suspension and remove the jack stand Vehicles equipped with a 4 6L 2V engine 9 Install the stabilizer bar For additional information refer to Stabilizer Bar in this section All vehicles 10 Install the parking brake cable bracket and a new bolt ...

Page 233: ...11 Connect the anti lock sensor wire 12 Lower the vehicle ...

Page 234: ...hese parts 1 Raise the vehicle on a hoist For additional information refer to Section 100 02 2 Support the No 1 crossmember with a jack stand 3 Remove both wheel and tire assemblies For additional information refer to Section 204 04 4 Remove both mufflers For additional information refer to Section 309 00 5 Remove the driveshaft For additional information refer to Section 205 01 6 Disconnect the p...

Page 235: ...ect the parking brake cable and conduits from the knuckles 5A968 5A969 9 Remove the bolts and the parking brake cable brackets 10 Remove the bolts and the rear brake lines 11 Remove the bolts and the ABS sensors ...

Page 236: ...move the nuts bolts and disconnect the shock absorbers 18125 from the lower suspension arm and bushings Discard the bolts and nuts 15 Lower the lower suspension arm and bushings and remove the jack stands 16 Support the rear subframe using the special tool 014 00765 17 Remove and discard the nuts from the subframe front bolts ...

Page 237: ...the special tool 014 00765 allowing the subframe to pivot on the front bolts 2 Remove the springs and the spring insulators 5536 Installation 1 NOTE Inspect the spring insulators for wear or damage Install new spring insulators if necessary Make sure the spring insulators are correctly installed on the springs ...

Page 238: ...tall the springs 1 Position the springs 2 Raise the subframe using the special tool 014 00765 3 Install new bolts 4 Remove and discard the subframe front bolts 5 Install new bolts and nuts Tighten the bolts ...

Page 239: ...talled between the lower suspension arm and bushing and the shock absorber Failure to do so can result in damage and failure of the lower suspension arm and bushing Connect the shock absorbers to the lower suspension arm and bushing and install new bolts and nuts 9 Clip the ABS sensor wires to the subframe 10 Install the ABS sensors and the bolts ...

Page 240: ...ct the parking brake cable and conduits to the lower suspension arm and bushings and install the bolts 13 Connect the parking brake cable and conduits to the knuckles 14 Connect the parking brake cable and conduits to the rear brake calipers and install the clips ...

Page 241: ...flers For additional information refer to Section 309 00 18 Install both wheel and tire assemblies For additional information refer to Section 204 04 19 Remove the jack stand from the No 1 crossmember 20 Bleed the brake system For additional information refer to Section 206 00 21 Check wheel alignment Adjust if necessary For additional information refer to Section 204 00 ...

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Page 243: ...talled if installation becomes necessary If substitution is necessary the part must be of the same finish and property class Torque values must be used as specified during reassembly to make sure of correct retention of these parts CAUTION When using a hoist that lifts the vehicle by the frame install new shock absorbers one at a time 1 Open the luggage compartment lid Position the carpet out of t...

Page 244: ...ck absorber 3 Position the shock absorber and install a new bolt and a new nut 4 NOTE When using a hoist that lifts the vehicle by the frame have an assistant guide the shock absorber into the body while lowering the hoist Lower the vehicle 5 Install a new insulator washer and nut 6 Position the carpet and close the luggage compartment lid ...

Page 245: ......

Page 246: ...perty class Torque values must be used as specified during reassembly to make sure of correct retention of these parts 1 Raise the vehicle For additional information refer to Section 100 02 2 Remove the wheel and tire assembly For additional information refer to Section 204 04 3 Disconnect the damper from the axle 1 Remove the bolt 2 Disconnect the damper 4 Remove the damper 1 Remove the nut 2 Rem...

Page 247: ...mper 1 Install the damper on the rear bracket 2 Install the outer washer 3 Install the nut Do not tighten the nut at this time 3 Connect the damper to the axle 1 Position the damper 2 Install the bolt 4 Tighten the nut ...

Page 248: ...5 Install the wheel and tire assembly For additional information refer to Section 204 04 6 Lower the vehicle ...

Page 249: ...5 A Professional Choke and Linkage Cleaner E8AZ 19A501 AA ESR M14P10 A Custom Bright Metal Cleaner 8A 19522 A ESR M5B194 B Aluminum Wheel Repair Compound E7AZ 19554 A ESA M4G280 A Tire Balance Weight Max tire balance weight 140g 5 oz per wheel 70g 2 5 oz per flange Tire inflation Tires See safety certification sticker located inside glove compartment door Torque Specifications Description Nm lb ft...

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Page 251: ...ssible injury Use only approved wheel assemblies WARNING Use only wheels and wheel nuts that have been designed for current model year Ford trucks Aftermarket wheels or wheel nuts may not fit or function correctly and can cause personal injury or damage the vehicle WARNING Always wear safety goggles or a face shield when performing any work with tire and wheel assemblies CAUTION Do not clean alumi...

Page 252: ......

Page 253: ... including full rated load capacity when inflated to recommended inflation pressures Tire and Wheel Runout Excessive radial and lateral runout of a wheel and tire assembly can cause roughness vibration wheel tramp tire wear and steering wheel tremor Before checking runout and to avoid false readings caused by temporary flat spots in the tires check runout only after the vehicle has been driven far...

Page 254: ...t damage Use off vehicle wheel and tire balancer only Be sure to follow the warnings when carrying out inspection and verification Road Test Verify the customer concern by carrying out a road test on a smooth road If any vibrations are apparent refer to Section 100 04 To maximize tire performance inspect for signs of incorrect inflation and uneven wear which may indicate a need for balancing rotat...

Page 255: ...tire in use 1 Inspect for signs of uneven wear that may indicate a need for balancing rotation front suspension alignment damaged tie rod or steering components 2 Check tires for cuts stone bruises abrasions blisters embedded objects 3 Tread wear indicators are molded into the bottom of the tread grooves Install a new tire when the indicator bands become visible Symptom Chart Symptom Chart Conditi...

Page 256: ...orn or damaged suspension components REFER to Section 204 00 Wheel and tire assembly out of balance BALANCE wheel and tire assembly Excessive lateral or radial runout of wheel REFER to Section 100 04 Wobble or shimmy Damaged wheel bearings REFER to Section 204 00 Loose or damaged suspension components REFER to Section 204 00 Bent wheel INSTALL a new wheel as necessary Damaged tire INSTALL a new ti...

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Page 258: ...area to improve adhesion of the sealer If the valve stem is close to the area remove it 4 Use a clean cloth to remove all cleaner or sanding dust 5 NOTE Do not use a torch containing oxyacetylene Heat the prepared area with a Heat Gun or a propane torch until aluminum wheel repair compound flows Apply the hot melt material over the prepared area using a liberal flow and wiping action Repair is mos...

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Page 260: ... 2 Loosen but do not remove the wheel nuts 2 CAUTION Never use the differential housing as a lifting point Raise the vehicle until the tire clears the ground For additional information refer to Section 100 02 3 CAUTION Do not use heat to loosen a seized wheel because heat can shorten the life of the wheel and damage the wheel bearings If the wheel cannot be removed by hand use a wheel puller to re...

Page 261: ...g surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion causing loss of control Position the wheel and tire on the vehicle 2 CAUTION Failure to tighten the wheel nuts in a star pattern can result in high brake disc runout which will speed up the development of brake roughness shudder and vibration Install the wheel nuts hand tight then lower the vehic...

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Page 263: ...ng Workshop Manual Driveline Angles Curb Specifications Engine L Engine Angle Deg Driveshaft Angle Deg Pinion Angle Deg 3 8 4 0 2 95 0 55 4 6 2V 4 0 3 61 0 55 General Specifications Item Specification Axle Capacities and Lubricant Specifications 7 5 inch rear axle a 1 5 liters 3 5 pints 8 8 inch rear axle a base and GT vehicles 1 9 liters 4 0 3 75 pints Traction Lok b 118 ml 4 oz Premium Rear Axle...

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Page 265: ... C Clutch Housing Alignment Adapter 308 021 T75L 4201 A Companion Flange Holding Tool 205 126 T78P 4851 A Companion Flange Runout Gauge 205 319 T92L 4851 B Dial Indicator with Bracketry 100 002 TOOL 4201 C or equivalent Dial Indicator Magnetic Base 100 D002 D78P 4201 B or equivalent Vibration Analyzer 100 F027 014 00344 Traction Lok Torque Tool 205 022 T66L 4204 A ...

Page 266: ...oise Some noise is acceptable and audible at certain speeds or under various driving conditions such as a newly paved blacktop road Slight noise is not detrimental to the operation of the axle and is considered normal With the Traction Lok differential axle slight chatter noise on slow turns after extended highway driving is considered acceptable and has no detrimental effect on the locking axle f...

Page 267: ...rubber lips can occasionally become hard like plastic with cracks at the oil lip contact point The contact point on the pinion flange may blacken indicating excessive heat Marks nicks gouges or rough surface texture on the seal journal of the pinion flange will also cause leaks When a seal leak occurs install a new seal and check the vent and the vent hose to make sure they are clean and free of f...

Page 268: ...er to Section 204 04 Driveline Angle Driveline angularity is the angular relationship between the engine crankshaft 6303 the driveshaft and the rear axle pinion Factors determining driveline angularity include ride height rear spring and engine mounts Driveline Angle An incorrect driveline pinion angle can often be detected by the driving condition in which the vibration occurs A vibration during ...

Page 269: ...ecial tool perpendicular to the wheel hub or axle flange bolt as close to the hub or flange face as possible Zero the indicator to allow the pointer to deflect either way 2 Rotate the hub or flange until the next bolt is contacted Record the measurement and continue until each bolt is checked The difference between the maximum and minimum contact readings will be the total wheel hub or axle flange...

Page 270: ...s axle shafts and wheel bearings as possible causes Follow the diagnostic procedures in Section 100 04 The noises described as follows usually have specific causes that can be diagnosed by observation as the unit is disassembled The initial clues are the type of noise heard during the road test Gear Howl and Whine Howling or whining of the ring gear and pinion is due to an incorrect gear pattern g...

Page 271: ...rs on the coast driving phase is usually caused by excessive clearance between the differential gear hub and the differential case bore Damage to a gear tooth on the coast side can cause a noise identical to a chuckle A very small tooth nick or ridge on the edge of a tooth can cause the noise Clean the gear tooth nick or ridge with a small grinding wheel If the damaged area is larger than 3 2 mm 1...

Page 272: ...e axle housing must also be installed if necessary Knock Knock which can occur on all driving phases has several causes including damaged teeth or gearset In most cases one of the following conditions will occur 1 A gear tooth damaged on the drive side is a common cause of the knock This can usually be corrected by grinding the damaged area ...

Page 273: ...occurs as engine torque shifts vehicle weight forcing changes in driveline angles preventing the driveshaft slip yoke from sliding on the output shaft To correct for this condition lubricate the slip yoke splines Total Backlash Check 1 Raise and support the vehicle Refer to Section 100 02 2 Remove the driveshaft Refer to Section 205 01 3 Install the special tool Clamp a rigid bar or pipe to the to...

Page 274: ... is moving at the speed in which the concern is occurring If the vehicle makes this noise remove the suspect axle shaft install a new bearing and a new axle seal Re evaluate the vehicle for noise before removing any internal components Bearing Rumble Bearing rumble sounds like marbles being tumbled This condition is usually caused by a worn damaged wheel bearing The lower pitch is because the whee...

Page 275: ...r jack stands to prevent tire flat spotting Engage the drivetrain and accelerate to the observed road test speed to verify the lubricant type 205 02B CLEAN and REFILL the axle to specification Axle overheating Lubricant level too low CHECK the lubricant level FILL the axle to specification Incorrect or contaminated lubricant type INSPECT the axle for damage REPAIR as necessary CLEAN and REFILL the...

Page 276: ...he wheels Rotate the driveshaft by turning the axle and measure the runout at the front the center and the rear of the driveshaft with the indicator If the runout exceeds 0 89 mm 0 035 inch at the front or center a new driveshaft must be installed If the front and center are within this limit but the rear runout is not mark the rear runout high point and proceed to Step 5 If the runout is within t...

Page 277: ...veshaft near the rear Position of the hose clamp head s can be determined by trial and error 8 Mark the rear of the driveshaft into four approximately equal sectors and number the marks 1 through 4 Install a hose clamp on the driveshaft with its head at position No 1 Check for vibration at road speed Recheck with the clamp at each of the other positions to find the position that shows minimum vibr...

Page 278: ...ase and ring gear runout checks Driveshaft Vibrates 1 Road test the vehicle to determine the critical vibration points Note the road speed the engine RPM and the shift lever positions at which the vibration occurs 2 Stop the vehicle place the transmission lever in neutral and run the engine through the critical speed ranges determined in Step 1 3 If no vibration is felt balance the driveshaft Refe...

Page 279: ...ction 205 02B Traction Lok Differential Check Road Test 1 Place one wheel on a dry surface and the other wheel on ice mud or snow 2 Gradually open the throttle to obtain maximum traction prior to break away The ability to move the vehicle demonstrates correct operation of a Traction Lok rear axle assembly 3 When starting with one wheel on an excessively slippery surface a slight application of the...

Page 280: ...1 3 Check the pinion flange for damage 4 Position the Companion Flange Runout Gauge on the pinion flange 5 Position the special tools on the pinion flange 6 Align the holes on the clamp plate with the holes in the pinion flange and install the bolts Snug the bolts evenly Item Part Number Description 1 Pilot part of 205 319 T92L 4851 B 2 354845 Pinion nut 3 205 319 T92L 4851 B Companion flange runo...

Page 281: ...until an acceptable runout is obtained If the flange runout is still more than 0 25 mm 0 010 inch install a new pinion flange 9 If excessive runout is still evident after installing a new pinion flange install a new ring and pinion Repeat the above checks until the runout is within specifications 10 Install the driveshaft Refer to Section 205 01 Tooth Contact Pattern Check Gearset 1 To check the g...

Page 282: ...ar or the pinion Contact Pattern Location In general desirable ring gear tooth patterns must have the following characteristics drive pattern on the drive side ring gear well centered on the tooth coast pattern on the coast side ring gear well centered on the tooth clearance between the pattern and the top of the tooth no hard lines where the pressure is high Acceptable ring gear tooth patterns fo...

Page 283: ...Correct pinion position shim that requires a decrease in backlash Correct pinion position shim that requires an increase in backlash ...

Page 284: ... the vehicle empty and all fluids full 5 Place the Inclinometer flush against the bottom of the driveshaft After the tool has been held on the driveshaft surface for 5 seconds push the ALT ZERO button to calibrate to zero degrees Remove the tool 6 To check the pinion angle rotate the driveshaft so that the rear axle pinion flange yoke ear is parallel to the floor Remove the U joint snap ring then ...

Page 285: ...rallel to the floor Remove the U joint snap ring then install the special tool Check and record the engine angle reading If the angle is not within specifications repair or adjust to obtain the correct angles Inspect the powertrain drivetrain mounts or frame rails for wear or damage ...

Page 286: ...cess leaving small pockets in the metal that will cause the axle housing to leak 1 To fill small pockets peen in a small amount of body lead 2 Seal the pocket Use epoxy sealer meeting Ford specification M 3D35A E 3 To fill large pockets drill and tap a shallow hole for a small setscrew Install the setscrew and seal it Use epoxy sealer meeting Ford specification M 3D35A E SECTION 205 00 Driveline S...

Page 287: ...for field repair Install a new axle housing if a weld is broken NOTE Most minor weld leaks are repairable This includes the puddle and fill welds that join the axle shaft tube to the axle housing on integral axles Seal the weld Use Devcon Aluminum Liquid F2 or equivalent meeting Ford specification M 3D35A E SECTION 205 00 Driveline System General Information 2003 Mustang Workshop Manual ...

Page 288: ...SPECIFICATIONS SECTION 205 01 Driveshaft 2003 Mustang Workshop Manual Torque Specifications Description Nm lb ft Pinion flange bolts 112 83 ...

Page 289: ... in the rear axle housing which transmits torque through the axle shafts to the drive SECTION 205 01 Driveshaft 2003 Mustang Workshop Manual Item Part Number Description 1 N800594 S100 Bolt 4 req d 2 4635 Universal joint U joint 3 4602 Driveshaft 4 Grease seal part of 4635 5 Needle bearings part of 4635 6 Bearing cup part of 4635 7 Thrust washer part of 4635 8 Spider part of 4635 9 4841 Driveshaft...

Page 290: ...ft slip yoke a welded tube assembly and a driveshaft centering socket yoke The splined driveshaft slip yoke permits the driveshaft to move forward and rearward on the transmission output shaft during drivetrain movement and during driveshaft removal and installation ...

Page 291: ...t each base of the bearing cup which control end play position the needle bearing and improve grease movement SECTION 205 01 Driveshaft 2003 Mustang Workshop Manual Item Part Number Description 1 4635 Universal joint U joint 2 Grease seal part of 4635 3 32 needle bearings part of 4635 4 Thrust washer part of 4635 5 Bearing cup part of 4635 6 Spider part of 4635 ...

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Page 293: ...n the rear axle pinion flange pilot Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange Pry only in the area shown with a suitable tool to disconnect the yoke from the flange Using a suitable tool as shown disconnect the driveshaft centering socket yoke from the rear axle pinion flange 4 CAUTION Do not allow the slip yoke to bottom on the transmission out...

Page 294: ...age 5 CAUTION Install the driveshaft with new bolts If new bolts are not available apply threadlock and sealer to the threads of the original bolts CAUTION Do not allow the slip yoke to bottom on the transmission output shaft CAUTION The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot To make sure that the yoke seats squarely on the flange tighten the bolts evenl...

Page 295: ...r mounts 3 Remove the nuts on the left side exhaust 4 Lower the muffler pipe enough to clear the flange Move the muffler assembly forward to disconnect the third exhaust hanger 5 Carry out the following 1 Place an index mark on the rear axle pinion flange and the driveshaft centering socket yoke SECTION 205 01 Driveshaft 2003 Mustang Workshop Manual Material Item Specification Threadlock and Seale...

Page 296: ...rward until the driveshaft slip yoke clears the transmission extension housing Place a paint index mark on the driveshaft slip yoke and the transmission output shaft Place a commercially available plug in the extension housing to prevent fluid leakage 8 CAUTION Install the driveshaft with new bolts If new bolts are not available apply threadlock and sealer to the threads of the original bolts CAUT...

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Page 298: ...enting or localizing fracture can result causing driveshaft failure during vehicle operation Place the driveshaft 4602 on a suitable workbench Be careful not to damage the tube 3 NOTE If components are not marked and therefore installed incorrectly driveline imbalance can occur Index mark the driveshaft components 4 Clamp the special tool in a vise SECTION 205 01 Driveshaft 2003 Mustang Workshop M...

Page 299: ...e the driveshaft slip yoke 4 Press on the spider to remove the remaining bearing cup 5 Remove the driveshaft slip yoke 7 Repeat Step 5 to remove the remaining bearing cups and spider from the driveshaft 8 Clean the yoke area at each end of the driveshaft Assembly 1 NOTE Universal joint service kits are to be installed as complete assemblies only Do not mix components from other U joint kits Instal...

Page 300: ...ings as required Remove the driveshaft from the special tool and install the snap ring 3 Repeat Steps 1 and 2 to install the opposite side of the driveshaft yoke 4 Inspect the driveshaft slip yoke Install new if necessary 5 Repeat Steps 1 and 2 to install the remaining new bearing cups spider driveshaft slip yoke and the snap rings 6 NOTE Do not strike the bearings Check the U joints for freedom o...

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Page 302: ... localizing fracture can result causing driveshaft failure during vehicle operation Place the driveshaft on a suitable workbench being careful not to damage the tube 3 NOTE If components are not marked and installed correctly driveline imbalance can occur Index mark the positions of the driveshaft components 4 Clamp the U joint tool in a vise 5 Remove all four of the snap rings SECTION 205 01 Driv...

Page 303: ...position the driveshaft in the U joint tool 2 Press out the bearing cup 3 Rotate the driveshaft 4 Press on the spider to remove the remaining bearing cup 5 Remove the spider 8 Clean the yoke area at the end of the driveshaft Assembly 1 NOTE Universal joint kits are to be installed as complete assemblies only Do not mix components from other U joint kits Install the spider 1 Start a new bearing cup...

Page 304: ...ange yoke Check the needle bearings for correct positioning 2 Position the driveshaft flange yoke 3 Position the driveshaft in the U joint tool 4 Press the bearing cup to just below the snap ring groove Repeat for the other bearing cup 4 NOTE Use the yellow snap rings supplied in the kit to assemble the universal joint U joint If difficulty is encountered with the yellow snap rings install the bla...

Page 305: ...Check the U joints for freedom of movement If binding strike the yoke with a brass or plastic hammer 6 Install the driveshaft For additional information refer to Driveshaft in this section ...

Page 306: ...m of the fill hole Clearance Tolerance and Adjustments Maximum ring gear back face runout 0 102 mm 0 004 in Maximum differential case runout 0 076 mm 0 003 in Differential side gear thrust washer thickness 0 762 mm 0 813 mm 0 030 in 0 032 in Differential pinion gear thrust washer thickness 0 762 mm 0 813 mm 0 030 in 0 032 in Maximum axle shaft end play 0 762 mm 0 030 in Ring gear backlash 0 203 mm...

Page 307: ...Bolt retaining the bearing cap to the differential case 105 77 Bolt retaining the ring gear to the differential case 105 77 ...

Page 308: ...nd Differential SECTION 205 02A Rear Drive Axle Differential Ford 7 5 Inch Ring Gear 2003 Mustang Workshop Manual Item Part Number Description 1 4236 Differential side gear 2 4228 Differential side gear thrust washer 3 4221 Differential bearing ...

Page 309: ...brake caliper 22 N601951 S2 Bolt 23 N804361 S100 Clip 24 Bolt 25 2C190 Rear brake anti lock sensor 26 2C101 Left hand rear disc brake adapter 27 2C100 Right hand rear disc brake adapter 28 N8015163 S190 Caliper anchor bolt 29 2C028 Rear wheel brake disc shield 30 N602726 S2 Bolt 3 req d 31 4616 Differential drive pinion bearing cup 32 4628 Rear axle pinion bearing cup 33 4630 Differential pinion b...

Page 310: ... housing adjust the differential bearing preload and the ring gear backlash The differential case 4204 is a one piece design with two openings to allow for assembly of the internal components and lubricant flow Two opposed tapered roller bearings differential bearings 4221 support the differential case in the axle housing Removable bearing caps 4010 retain the differential assembly in the axle hou...

Page 311: ...sing Cover in this section 5 Remove the differential pinion shaft 4211 1 Remove the differential pinion shaft lock bolt 4241 2 Remove the differential pinion shaft 6 CAUTION Do not damage the rubber O ring in the axle shaft groove Remove the U washer 4N237 1 Push the axle shafts 4234 inboard 2 Remove the U washer 7 CAUTION Damage to the rear brake anti lock sensor 2C190 may occur if it is not remo...

Page 312: ...ricate the lip of the wheel bearing oil seal Use Premium Long Life Grease XG 1 C or equivalent meeting Ford specification ESA M1C75 B 2 CAUTION Do not damage the wheel bearing oil seal Install the two axle shafts 3 CAUTION Do not damage the rubber O ring in the axle shaft groove Install the U washer ...

Page 313: ...ential pinion shaft with the case lock bolt hole 2 Install a new differential pinion shaft lock bolt 5 Install the differential housing cover and fill the rear axle with the specified lubrication For additional information refer to Differential Housing Cover in this section 6 Install the rear brake anti lock sensor For additional information refer to Section 206 09A 7 Install the rear brakes For a...

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Page 315: ... vent may be plugged Using the special tools remove the rear wheel bearing and wheel bearing oil seal SECTION 205 02A Rear Drive Axle Differential Ford 7 5 Inch Ring Gear 2003 Mustang Workshop Manual Special Tool s Adapter for 303 224 205 153 T80T 4000 W Installer Axle Shaft Bearing 205 124 T78P 1225 A Installer Rear Axle Oil Seal 205 390 T97T 1177 B Remover Axle Bearing 205 219 T85L 1225 AH Slide...

Page 316: ... new rear wheel bearing 3 Lubricate the lip of the new wheel bearing oil seal Use Premium Long Life Grease XG 1 C or equivalent meeting Ford specification ESA M1C75 B 4 Using the special tools install the new wheel bearing oil seal 5 Install the axle shaft For additional information refer to Axle Shaft in this section ...

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Page 318: ...mation refer to Section 206 04 4 CAUTION Index mark the driveshaft flange and pinion flange 4851 to maintain initial balance during installation CAUTION The driveshaft centering socket yoke fits tightly on the pinion flange pilot Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange Pry only in the area shown with a suitable tool to disconnect the yoke from...

Page 319: ...intain rotation of the drive pinion gear through several revolutions 6 CAUTION After removing the nut discard it Use a new nut for installation Use the special tool to hold the pinion flange while removing the nut 7 Index mark the pinion flange and drive pinion gear stem to maintain initial balance during ...

Page 320: ...g the flange Polish the seal journal with fine crocus cloth if necessary 2 Lubricate the pinion flange splines Use SAE 80W 90 Premium Rear Axle Lubricant XY 80W90 QL or equivalent meeting Ford specification WSP M2C197 A 3 NOTE Disregard the index marks if installing a new pinion flange Position the pinion flange 4 Using the special tools install the pinion flange ...

Page 321: ...gs then tighten the nut to specification If the preload recorded prior to disassembly is higher than the specification for used bearings then tighten the nut to the original reading as recorded Refer to the torque specification for used differential pinion bearings in the Specifications portion of this section 6 CAUTION Align the index marks CAUTION Install the driveshaft with new bolts If new bol...

Page 322: ...7 Install the rear brake calipers For additional information refer to Section 206 04 8 Install the rear wheel and tire assemblies For additional information refer to Section 204 04 9 Lower the vehicle ...

Page 323: ...ean and free of oil before applying the new silicone sealant To prevent contamination cover the inside of the rear axle 4001 prior to cleaning the machined surface Clean the differential housing and the differential housing cover gasket mating surfaces 2 CAUTION Install the differential housing cover within 15 minutes of applying the silicone or it will be necessary to remove and reapply new seala...

Page 324: ...OTE In vehicle repair refill capacities are determined by filling the rear axle with the specified lubricant to 6 4 14 3 mm 1 4 9 16 in below the bottom of the fill hole Fill the rear axle to the level shown approximately 1 54 1 66 liters 3 25 3 50 pints of lubricant and install the filler plug Use SAE 80W 90 Premium Rear Axle Lubricant XY 80W90 QL or equivalent meeting Ford specification WSP M2C1...

Page 325: ......

Page 326: ...essary the part must be of the same finish and property class Torque values must be used as specified during reassembly to make sure of correct retention of these parts 1 Remove the upper arm and bushing 5500 For additional information refer to Section 204 02 2 Using the special tools remove the bushing Installation 1 Using the special tools install the bushing SECTION 205 02A Rear Drive Axle Diff...

Page 327: ...Using a suitable calibrated micrometer measure the bushing as shown If not within specifications adjust as necessary 3 Install the upper arm and bushing For additional information refer to Section 204 02 ...

Page 328: ...ol s Adapter for 205 S127 205 105 T76P 4020 A3 Adapter for 205 S127 205 109 T76P 4020 A9 Adapter for 205 S127 205 110 T76P 4020 A10 Adapter for 205 S127 205 111 T76P 4020 A11 Adapter for 205 S127 205 125 T78P 4020 A15 Adapter for 303 224 205 153 T80T 4000 W Gauge Tube 205 D034 D80T 4020 F49 or equivalent Handle Long 205 D055 D81L 4000 A or ...

Page 329: ...T53T 4621 C Installer Drive Pinion Bearing Cup 205 054 T71P 4616 A Installer Drive Pinion Flange 205 002 TOOL 4858 E or equivalent Installer Drive Pinion Oil Seal 205 133 T79P 4676 A Plate Bearing Oil Seal 205 090 T75L 1165 B Protector Drive Pinion Thread 205 460 Puller Bearing 205 D064 D84L 1123 A or equivalent ...

Page 330: ...ove the pinion flange For additional information refer to Drive Pinion Flange and Drive Pinion Seal in this section 3 Force the rear axle drive pinion seal metal flange up Install gripping pliers and strike with a hammer to remove the seal 4 Remove the rear axle drive pinion shaft oil slinger 4670 5 Using the special tool and a soft faced hammer drive the pinion assembly out of the outer different...

Page 331: ...62 8 Using the special tool and a suitable press remove the inner differential pinion bearing 4630 9 NOTE Do not remove the pinion bearing cups from the differential housing unless the cups are damaged To remove the bearing cups tap alternately with a brass drift of suitable length on opposite ...

Page 332: ...outer pinion bearing cups in their respective bores 1 After placing the inner and outer bearing cups in their bores place the special tool on the inner bearing cup 2 Place the special tool on the outer bearing cup 3 Install the special tool 2 Tighten the special tool to seat the pinion bearing cups in their bores 3 CAUTION Always install new differential pinion bearings when installing new pinion ...

Page 333: ...ecial tools drive the outer differential drive pinion bearing cup 4616 into the differential housing 5 Using the special tools drive the inner rear axle pinion bearing cup 4628 into the differential housing 6 CAUTION Always install new differential pinion bearings when installing new pinion bearing cups NOTE If the feeler gauge can fit between a cup and the bottom of its bore at any point around t...

Page 334: ...ion the Adapter for 205 S127 2 Position the Adapter for 205 S127 3 Position the inner pinion bearing 4 Position the Adapter for 205 S127 5 Position the Adapter for 205 S127 6 Position the outer pinion bearing 7 Thread on the Adapter for 205 S127 8 NOTE This step duplicates final differential pinion bearing preload Using a Nm inch pound torque wrench tighten the special tool to specification ...

Page 335: ...ll the special tool 1 Position the special tool Item Part Number Description 1 205 109 Adapter for 205 S127 T76P 4020 A9 2 205 105 Adapter for 205 S127 T76P 4020 A3 1 612 inch O D 3 4630 Rear inner pinion bearing 4 205 125 Adapter for 205 S127 T78P 4020 A15 0 894 inch thick 5 205 110 Adapter for 205 S127 T76P 4020 A10 1 7 inch thick 6 4621 Front outer pinion bearing 7 205 111 Adapter for 205 S127 ...

Page 336: ...selection Use a drive pinion bearing adjustment shim as a gauge for shim selection After determining the correct shim thickness remove the special tools 12 Position the correct thickness drive pinion bearing adjustment shim and the differential pinion bearing on the drive pinion gear Using a suitable press and the special tools press the differential pinion bearing until it seats firmly against th...

Page 337: ...ll the drive pinion assembly drive pinion shims bearing and the collapsible spacer into the differential housing bore 17 NOTE Coat the rear axle drive pinion seal lips with Premium Long Life Grease XG 1 C or equivalent meeting Ford specification ESA M1C75 B Place the rear axle drive pinion seal on the special tool ...

Page 338: ...the seal bore and use the special tool to drive the seal into place 19 Lubricate the pinion flange splines Use SAE 80W 90 Premium Rear Axle Lubricant XY 80W90 QL or equivalent meeting Ford specification WSP M2C197 A 20 NOTE Disregard the index marks if installing a new pinion flange Position the pinion flange 21 Using the special tools install the pinion flange ...

Page 339: ...fications portion of this section For used differential pinion bearings if the preload recorded prior to disassembly is lower than the specification for used bearings then tighten the nut to specification Refer to torque specifications for used differential pinion bearings in the Specifications portion of this section For used differential pinion bearings if the preload recorded prior to disassemb...

Page 340: ...ft centering socket yoke fits tightly on the pinion flange pilot To make sure that the yoke seats squarely on the flange tighten the bolts evenly in a cross pattern as shown Connect the driveshaft For additional information refer to Section 205 01 25 Lower the vehicle ...

Page 341: ...ase 4204 after removing the axle shafts 4234 SECTION 205 02A Rear Drive Axle Differential Ford 7 5 Inch Ring Gear 2003 Mustang Workshop Manual Special Tool s 2 Jaw Puller 205 D072 D97L 4221 A or equivalent Dial Indicator Gauge with Holding Fixture 100 002 TOOL 4201 C or equivalent Gauge Clutch Housing 308 021 T75L 4201 A or equivalent Installer Differential Shim 205 220 T85L 4067 AH Installer Diff...

Page 342: ...ecial tool measure and note the ring gear backface runout 6 CAUTION Mark the position and location of the bearing caps as the arrows may not be visible Always install the bearing caps in their identical locations and positions Remove the bearing caps 1 Remove the bolts 2 Remove the bearing caps 7 WARNING Do not allow the differential assembly to fall Failure to follow these instructions may result...

Page 343: ...ification proceed to the appropriate procedure as necessary Drive Pinion Differential Case and Ring Gear in this section or to Installation in this procedure If the ring gear backface runout measurement taken at the beginning of this procedure exceeds the specification the cause may be a warped ring gear differential case differential bearing damage Proceed as follows to verify the cause of the ex...

Page 344: ... does not exceed the specification install a new ring gear and drive pinion gear For additional information refer to Drive Pinion in this section and to Installation in this procedure If the runout exceeds the specification the ring gear is true and the concern is due to either differential case differential bearing damage Proceed as follows 14 Remove the differential assembly from the differentia...

Page 345: ...the differential bearing cups and differential bearing shims in the differential housing Install the bearing caps and bolts 18 Position the special tool 1 Rotate the differential case to verify that the differential bearings have seated correctly 2 Position the special tool 19 Measure the differential case runout ...

Page 346: ...e differential housing Installation All axles 1 Position the ring gear and the differential case Align the bolt holes by starting two bolts through the holes in the differential case and the ring gear Press the ring gear on the differential case 2 Install the bolts Apply Stud and Bearing Mount EOAZ 19554 BA or equivalent meeting Ford specification WSK M2G349 A1 to the bolt threads 3 With the pinio...

Page 347: ... locations and positions NOTE Apply pressure toward the left side to make sure the left differential bearing cup seats correctly Install the left bearing cap and loosely install the bolts 6 Install progressively larger differential bearing shims on the right side until the largest shim selected is installed by hand ...

Page 348: ...sh is within the specification refer to Backlash within specification in this procedure The specification shown is the full allowable range For the preferred range refer to Specifications in this section If a zero backlash condition occurs refer to Zero backlash in this procedure If backlash is not within the specification refer to Backlash not within specification in this procedure Backlash Chang...

Page 349: ...ow backlash indication 11 Install the bearing caps and the bolts 0 076 0 003 0 101 0 004 0 101 0 004 0 152 0 006 0 127 0 005 0 152 0 006 0 152 0 006 0 203 0 008 0 177 0 007 0 254 0 010 0 203 0 008 0 254 0 010 0 228 0 009 0 304 0 012 0 254 0 010 0 355 0 014 0 279 0 011 0 355 0 014 0 304 0 012 0 406 0 016 0 330 0 013 0 457 0 018 0 335 0 014 0 457 0 018 0 381 0 015 0 508 0 020 ...

Page 350: ...Backlash not within specification 14 To increase or decrease the backlash remove the bearing caps and install a thicker shim and thinner shim accordingly If backlash is not within the specification increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount 15 Install the bearing caps and the bolts ...

Page 351: ...ash not within specification in this procedure The specification shown is the full allowable range For the preferred range refer to Specifications in this section Backlash within specification 18 Remove the bolts and bearing caps 19 Set the differential bearing preload 1 To establish differential bearing preload increase both left and right differential bearing shim sizes by the specification show...

Page 352: ...e range For the preferred range refer to Specifications in this section 22 Install the axle shafts For additional information refer to Axle Shaft in this section 23 Install the differential housing cover and refill the rear axle with specified lubricant For additional information refer to Differential Housing Cover in this section ...

Page 353: ...24 Lower the vehicle ...

Page 354: ...r additional information refer to Section 204 04 4 CAUTION Index mark the driveshaft flange and pinion flange 4851 to maintain initial balance during installation CAUTION The driveshaft centering socket yoke fits tightly on the pinion flange pilot Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange Pry only in the area shown with a suitable tool to discon...

Page 355: ... additional information refer to Section 206 09A 6 CAUTION Index mark the brake discs and the wheel studs prior to brake disc removal CAUTION Do not allow the calipers to hang from the brake hoses Remove the rear brake discs For additional information refer to Section 206 04 7 CAUTION Secure the differential housing 4010 to the jack with a suitable strap Support the differential housing with a sui...

Page 356: ...the axle 9 Remove and discard the nuts and bolts retaining the upper suspension arm and bushings to the differential housing 10 Lower the axle slightly and remove the springs 11 Remove and discard the nuts and bolts retaining the lower suspension arm and bushings to the axle ...

Page 357: ...squarely on the flange tighten the bolts evenly in a cross pattern as shown CAUTION Raise the suspension to the reference marks on the rear shock absorbers before tightening the suspension fasteners NOTE Apply High Temperature Nickel Anti Sieze Lubricant F6AZ 9L494 AA meeting Ford specification ESE M124A A to the rear anti lock brake sensor body where it will make contact when installed To install...

Page 358: ......

Page 359: ...tion 2 Remove the bolts 3 CAUTION Do not damage the threads in the bolt holes Insert a punch in the bolt holes and drive off the ring gear SECTION 205 02A Rear Drive Axle Differential Ford 7 5 Inch Ring Gear 2003 Mustang Workshop Manual Special Tool s 2 Jaw Puller 205 D072 D97L 4221 A or equivalent Installer Differential Side Bearing 205 009 T57L 4221 A1 Step Plate 205 D016 D80L 630 5 or equivalen...

Page 360: ...l tools remove the differential bearings 4221 if necessary 5 Remove the bolt 6 Remove the differential pinion shaft 4211 7 Rotate and remove the differential pinion gears 4215 and differential pinion thrust washers 4230 ...

Page 361: ... journals and assemble the washers to the gears Use SAE 80W 90 Premium Rear Axle Lubricant XY 80W90 QL or equivalent meeting Ford specification WSP M2C197 A 2 Lubricate the differential pinion thrust washers and the differential pinion gears and assemble the washers to the gears Use SAE 80W 90 Premium Rear Axle Lubricant XY 80W90 QL or equivalent meeting Ford specification WSP M2C197 A ...

Page 362: ...otate the pinion gears to align with the differential pinion shaft bore 5 Insert the differential pinion shaft Align the hole in the differential pinion shaft with the hole in the differential case 6 NOTE If a new bolt is unavailable coat the original bolt threads with Threadlock and Sealer EOAZ 19554 AA or equivalent meeting Ford specifications WSK M2G351 A5 prior to ...

Page 363: ...on the ring gear and the differential case Align the bolt holes by starting two bolts through the holes in the differential case and the ring gear Press the ring gear on the differential case 9 Install the bolts Apply Stud and Bearing Mount EOAZ 19554 BA or equivalent meeting Ford specification WSK M2G349 A1 to the bolt threads ...

Page 364: ...10 Install the differential case For additional information refer to Differential Case in this section ...

Page 365: ... 19562 AA ESB M4G92 A Threadlock and Sealer EOAZ 19554 AA WSK M2G351 A5 Lubricant Fill Level Checks Additive Friction Modifier 118 ml 4 oz Approximate axle fill capacity a b 1 66 1 77 liters 3 5 3 75 pints 6 4 14 3 mm 1 4 9 16 in below the bottom of the fill hole Clearance Tolerance and Adjustments Maximum ring gear back face runout 0 102 mm 0 004 in Maximum differential case runout 0 076 mm 0 003...

Page 366: ...d used pinion bearings 0 9 1 5 8 14 Pinion bearing preload new pinion bearings 1 8 3 3 16 29 Adapter for 205 S127 2 2 20 Bolt retaining the bearing cap to the differential case 105 77 Bolt retaining the ring gear to the differential case 105 77 ...

Page 367: ...nd Differential SECTION 205 02B Rear Drive Axle Differential Ford 8 8 Inch Ring Gear 2003 Mustang Workshop Manual Item Part Number Description 1 4236 Differential side gear 2 4228 Differential side gear thrust washer 3 4221 Differential bearing ...

Page 368: ... 22 N601951 S2 Bolt 23 N804361 S100 Clip 24 Bolt part of 4010 25 2C190 Rear brake anti lock sensor 26 2C101 Left hand rear disc brake adapter 27 2C100 Right hand rear disc brake adapter 28 N8015163 S190 Caliper anchor bolt 29 2C028 Rear wheel brake disc shield 30 N602726 S2 Bolt 3 req d 31 4616 Differential drive pinion bearing cup 32 4628 Rear axle pinion bearing cup 33 4630 Differential pinion b...

Page 369: ...r axle housing adjust the differential bearing preload and the ring gear backlash The differential case 4204 is a one piece design with two openings to allow for assembly of the internal components and lubricant flow Two opposed tapered roller bearings differential bearings 4221 support the differential case in the axle housing Removable bearing caps 4010 retain the differential assembly in the ax...

Page 370: ...sing Cover in this section 5 Remove the differential pinion shaft 4211 1 Remove the differential pinion shaft lock bolt 4241 2 Remove the differential pinion shaft 6 CAUTION Do not damage the rubber O ring in the axle shaft groove Remove the U washer 4N237 1 Push the axle shafts 4234 inboard 2 Remove the U washer 7 CAUTION Damage to the rear brake anti lock sensor 2C190 may occur if it is not remo...

Page 371: ...ricate the lip of the wheel bearing oil seal Use Premium Long Life Grease XG 1 C or equivalent meeting Ford specification ESA M1C75 B 2 CAUTION Do not damage the wheel bearing oil seal Install the two axle shafts 3 CAUTION Do not damage the rubber O ring in the axle shaft groove Install the U washer ...

Page 372: ...ential pinion shaft with the case lock bolt hole 2 Install a new differential pinion shaft lock bolt 5 Install the differential housing cover and fill the rear axle with the specified lubrication For additional information refer to Differential Housing Cover in this section 6 Install the rear brake anti lock sensor For additional information refer to Section 206 09A 7 Install the rear brakes For a...

Page 373: ......

Page 374: ... vent may be plugged Using the special tools remove the rear wheel bearing and wheel bearing oil seal SECTION 205 02B Rear Drive Axle Differential Ford 8 8 Inch Ring Gear 2003 Mustang Workshop Manual Special Tool s Adapter for 303 224 205 153 T80T 4000 W Installer Axle Shaft Bearing 205 124 T78P 1225 A Installer Rear Axle Oil Seal 205 390 T97T 1177 B Remover Axle Bearing 205 219 T85L 1225 AH Slide...

Page 375: ... new rear wheel bearing 3 Lubricate the lip of the new wheel bearing oil seal Use Premium Long Life Grease XG 1 C or equivalent meeting Ford specification ESA M1C75 B 4 Using the special tools install the new wheel bearing oil seal 5 Install the axle shaft For additional information refer to Axle Shaft in this section ...

Page 376: ......

Page 377: ...ean and free of oil before applying the new silicone sealant To prevent contamination cover the inside of the rear axle 4001 prior to cleaning the machined surface Clean the differential housing and the differential housing cover gasket mating surfaces 2 CAUTION Install the differential housing cover within 15 minutes of applying the silicone or it will be necessary to remove and reapply new seala...

Page 378: ... 19B546 A or equivalent meeting Ford specification EST M2C118 A before filling the axle with the new lubricant NOTE In vehicle repair refill capacities are determined by filling the rear axle with the specified lubricant to 6 4 14 3 mm 1 4 9 16 in below the bottom of the fill hole Fill the rear axle to the level shown approximately 1 66 1 77 liters 3 5 3 75 pints of lubricant and install the fille...

Page 379: ......

Page 380: ...essary the part must be of the same finish and property class Torque values must be used as specified during reassembly to make sure of correct retention of these parts 1 Remove the upper arm and bushing 5500 For additional information refer to Section 204 02 2 Using the special tools remove the bushing Installation 1 Using the special tools install the bushing SECTION 205 02B Rear Drive Axle Diff...

Page 381: ...Using a suitable calibrated micrometer measure the bushing as shown If not within specifications adjust as necessary 3 Install the upper arm and bushing For additional information refer to Section 204 02 ...

Page 382: ...ter for 205 S127 205 105 T76P 4020 A3 Adapter for 205 S127 205 109 T76P 4020 A9 Adapter for 205 S127 205 110 T76P 4020 A10 Adapter for 205 S127 205 111 T76P 4020 A11 Adapter for 205 S127 205 129 T79P 4020 A18 Adapter for 205 S127 205 130 T79P 4020 A19 or equivalent Adapter for 303 224 Short Handle 205 153 T80T 4000 W Handle 205 D055 D81L 4000 A or ...

Page 383: ... 4621 C Installer Drive Pinion Bearing Cup 205 024 T67P 4616 A Installer Drive Pinion Bearing Outer 205 231 T85T 4616 AH Installer Drive Pinion Flange 205 002 TOOL 4858 E or equivalent Installer Drive Pinion Oil Seal 205 133 T79P 4676 A Plate Bearing Oil Seal 205 090 T75L 1165 B Protector Drive Pinion Thread 205 460 ...

Page 384: ... additional information refer to Drive Pinion Flange and Drive Pinion Seal in this section 3 Force the rear axle drive pinion seal metal flange up Install gripping pliers and strike with a hammer to remove the seal 4 Remove the rear axle drive pinion shaft oil slinger 4670 5 Using the special tool and a soft faced hammer drive the pinion assembly out of the outer differential pinion bearing 4621 a...

Page 385: ...er 4662 8 Using the special tool and a suitable press remove the inner differential pinion bearing 4630 9 NOTE Do not remove the pinion bearing cups from the differential housing unless the cups are damaged Using the special tools remove the outer differential drive pinion bearing cup 4616 ...

Page 386: ...ial tools and the inner and outer pinion bearing cups in their respective bores 1 After placing the inner and outer bearing cups in their bores place the special tool on the inner bearing cup 2 Place the special tool on the outer bearing cup 3 Install the special tool 2 Tighten the special tool to seat the pinion bearing cups in their bores 3 CAUTION Always install new differential pinion bearings...

Page 387: ...steps 4 Using the special tools drive the outer differential drive pinion bearing cup into the differential housing 5 Using the special tools drive the inner rear axle pinion bearing cup into the differential housing 6 CAUTION Always install new differential pinion bearings when installing new pinion bearing cups NOTE If the feeler gauge can fit between a cup and the bottom of its bore at any poin...

Page 388: ...es final differential pinion bearing preload Item Part Number Description 1 205 109 Adapter for 205 S127 T76P 4020 A9 2 205 105 Adapter for 205 S127 T76P 4020 A3 1 612 inch O D 3 4630 Rear inner pinion bearing 4 205 129 Adapter for 205 S127 T79P 4020 A18 1 1884 inch thick 5 205 110 Adapter for 205 S127 T76P 4020 A10 1 7 inch thick 6 4621 Front outer pinion bearing 7 205 111 Adapter for 205 S127 T7...

Page 389: ...sition the special tool 2 Install the bearing caps 3 Install the four bolts 11 NOTE Use only flat clean drive pinion bearing adjustment shims 4663 NOTE Selection of too thick a shim results in a deep tooth contact at final assembly Do not attempt to force the shim between the special tools A slight drag indicates correct shim selection Use a drive pinion bearing adjustment shim as a gauge for shim...

Page 390: ...ear Using a suitable press and the special tools press the differential pinion bearing until it seats firmly against the drive pinion gear 13 Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder 14 Install the outer differential pinion bearing 15 Install the rear axle drive pinion shaft oil slinger ...

Page 391: ... with Premium Long Life Grease XG 1 C or equivalent meeting Ford specification ESA M1C75 B Place the rear axle drive pinion seal on the special tool 18 CAUTION If the rear axle drive pinion seal becomes misaligned during installation remove it and install a new one Position the rear axle drive pinion seal in the seal bore and use the special tool to drive the seal into place ...

Page 392: ...e 22 CAUTION Do not under any circumstance loosen the nut to reduce preload If it is necessary to reduce preload install a new collapsible spacer and nut CAUTION Remove the special tool while taking readings with the Nm inch pound torque wrench Tighten the nut to set the preload Rotate the drive pinion occasionally to make sure the differential pinion bearings seat correctly Take frequent differen...

Page 393: ... specification for used bearings then tighten the nut to the original reading as recorded Final assembly 23 Install the differential assembly in the differential housing For additional information refer to Differential Case in this section 24 CAUTION Align the index marks CAUTION Install the driveshaft with new bolts If new bolts are not available apply Threadlock and Sealer EOAZ 19554 AA or equiv...

Page 394: ......

Page 395: ...se 4204 after removing the axle shafts 4234 SECTION 205 02B Rear Drive Axle Differential Ford 8 8 Inch Ring Gear 2003 Mustang Workshop Manual Special Tool s 2 Jaw Puller 205 D072 D97L 4221 A or equivalent Dial Indicator Gauge with Holding Fixture 100 002 TOOL 4201 C or equivalent Gauge Clutch Housing 308 021 T75L 4201 A or equivalent Installer Differential Shim 205 220 T85L 4067 AH Installer Diffe...

Page 396: ...ecial tool measure and note the ring gear backface runout 6 CAUTION Mark the position and location of the bearing caps as the arrows may not be visible Always install the bearing caps in their identical locations and positions Remove the bearing caps 1 Remove the bolts 2 Remove the bearing caps 7 WARNING Do not allow the differential assembly to fall Failure to follow these instructions may result...

Page 397: ...riate procedure as necessary Drive Pinion Differential Case and Ring Gear Conventional or Differential Case and Ring Gear Traction Lok in this section or to Installation in this procedure If the ring gear backface runout measurement taken at the beginning of this procedure exceeded the specification the cause may be a warped ring gear differential case differential bearing damage Proceed as follow...

Page 398: ... does not exceed the specification install a new ring gear and drive pinion gear For additional information refer to Drive Pinion in this section and to Installation in this procedure If the runout exceeds the specification the ring gear is true and the concern is due to either differential case differential bearing damage Proceed as follows 14 Remove the differential assembly from the differentia...

Page 399: ...the differential bearing cups and differential bearing shims in the differential housing Install the bearing caps and bolts 18 Position the special tool 1 Rotate the differential case to verify that the differential bearings have seated correctly 2 Position the special tool 19 Measure the differential case runout ...

Page 400: ... differential assembly from the differential housing Installation All axles 1 Position the ring gear and the differential case Align the bolt holes by starting two bolts through the holes in the differential case and the ring gear Press the ring gear on the differential case 2 Install the bolts Apply Stud and Bearing Mount EOAZ 19554 BA or equivalent meeting Ford specification WSK M2G349 A1 to the...

Page 401: ... locations and positions NOTE Apply pressure toward the left side to make sure the left differential bearing cup seats correctly Install the left bearing cap and loosely install the bolts 6 Install progressively larger differential bearing shims on the right side until the largest shim selected is installed by hand ...

Page 402: ...sh is within the specification refer to Backlash within specification in this procedure The specification shown is the full allowable range For the preferred range refer to Specifications in this section If a zero backlash condition occurs refer to Zero backlash in this procedure If backlash is not within the specification refer to Backlash not within specification in this procedure Backlash Chang...

Page 403: ...ow backlash indication 11 Install the bearing caps and the bolts 0 076 0 003 0 101 0 004 0 101 0 004 0 152 0 006 0 127 0 005 0 152 0 006 0 152 0 006 0 203 0 008 0 177 0 007 0 254 0 010 0 203 0 008 0 254 0 010 0 228 0 009 0 304 0 012 0 254 0 010 0 355 0 014 0 279 0 011 0 355 0 014 0 304 0 012 0 406 0 016 0 330 0 013 0 457 0 018 0 335 0 014 0 457 0 018 0 381 0 015 0 508 0 020 ...

Page 404: ...e Backlash not within specification 14 To increase or decrease the backlash remove the bearing caps and install a thicker shim and thinner shim accordingly If backlash is not within the specification increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount 15 Install the bearing caps and the bolts ...

Page 405: ...sh not within specification in this procedure The specification shown is the full allowable range For the preferred range refer to Specifications in this section Backlash within specification 18 Remove the bolts and bearing caps 19 Set the differential bearing preload 1 To establish differential bearing preload increase both left and right differential bearing shim sizes by the specification shown...

Page 406: ...e range For the preferred range refer to Specifications in this section 22 Install the axle shafts For additional information refer to Axle Shaft in this section 23 Install the differential housing cover and refill the rear axle with specified lubricant For additional information refer to Differential Housing Cover in this section ...

Page 407: ...24 Lower the vehicle ...

Page 408: ...move the rear wheel and tire assemblies For additional information refer to Section 204 04 4 NOTE If necessary use Rust Penetrant and Inhibitor F2AZ 19A501 A meeting Ford specification ESR M99C56 A to loosen the sensor for removal Remove the rear anti lock brake sensors from the rear disc brake adapters For additional information refer to Section 206 09A 5 Disconnect the parking brake cables and c...

Page 409: ...06 04 8 CAUTION Index mark the driveshaft flange and pinion flange 4851 to maintain initial balance during installation CAUTION The driveshaft centering socket yoke fits tightly on the pinion flange pilot Never hammer on the driveshaft or any of its components to disconnect the yoke from the flange Pry only in the area shown with a suitable tool to disconnect the yoke from the flange Disconnect an...

Page 410: ...fer to Section 204 02 10 Position a suitable transmission jack under the differential housing 4010 for support and strap it securely in place 11 Remove and discard the nuts and bolts retaining the upper suspension arm and bushings to the differential housing ...

Page 411: ...rs to the axle 13 Lower the differential housing to unload the rear springs 14 Remove the rear springs 15 Remove and discard the nuts and bolts retaining the lower suspension arm and bushings to the axle 16 Disconnect the lower suspension arm and bushings from the axle ...

Page 412: ...ge pilot To make sure that the yoke seats squarely on the flange tighten the bolts evenly in a cross pattern as shown CAUTION Raise the suspension to the reference marks on the rear shock absorbers before tightening the suspension fasteners NOTE Apply High Temperature Nickel Anti Sieze Lubricant F6AZ 9L494 AA meeting Ford specification ESE M124A A to the rear anti lock brake sensor body where it w...

Page 413: ......

Page 414: ...s section 2 Remove the bolts 3 CAUTION Do not damage the threads in the bolt holes Insert a punch in the bolt holes and drive off the ring gear SECTION 205 02B Rear Drive Axle Differential Ford 8 8 Inch Ring Gear 2003 Mustang Workshop Manual Special Tool s 2 Jaw Puller 205 D072 D97L 4221 A or equivalent Installer Differential Side Bearing 205 010 T57L 4221 A2 Step Plate 205 D061 D83T 4205 C2 or eq...

Page 415: ...l tools remove the differential bearings 4221 if necessary 5 Remove the bolt 6 Remove the differential pinion shaft 4211 7 Rotate and remove the differential pinion gears 4215 and differential pinion thrust washers 4230 ...

Page 416: ...nd assemble the washers to the gears Use SAE 75W 140 High Performance Rear Axle Lubricant F1TZ 19580 B or equivalent meeting Ford specification WSL M2C192 A 2 Lubricate the differential pinion thrust washers and the differential pinion gears and assemble the washers to the gears Use SAE 75W 140 High Performance Rear Axle Lubricant F1TZ 19580 B or equivalent meeting Ford specification WSL M2C192 A ...

Page 417: ...e the differential pinion gears with the differential side gears and rotate the pinion gears to align with the differential pinion shaft bore 5 Insert the differential pinion shaft Align the hole in the differential pinion shaft with the hole in the differential case 6 Install a new bolt finger tight ...

Page 418: ...ing two bolts through the holes in the differential case and the ring gear Press the ring gear on the differential case 9 Install the bolts Apply Stud and Bearing Mount EOAZ 19554 BA or equivalent meeting Ford specification WSK M2G349 A1 to the bolt threads 10 Install the differential assembly For additional information refer to Differential Case in this ...

Page 419: ...section ...

Page 420: ...ase in this section 2 Remove the 10 bolts SECTION 205 02B Rear Drive Axle Differential Ford 8 8 Inch Ring Gear 2003 Mustang Workshop Manual Special Tool s 2 Jaw Puller 205 D072 D97L 4221 A or equivalent Gauge Differential Clutch 205 022 T66L 4204 A Gauge Differential Clutch 205 135 T80P 4946 A Installer Differential Side Bearing 205 010 T57L 4221 A2 Step Plate 205 D061 D83T 4205 C2 or equivalent ...

Page 421: ...a punch in the bolt holes and drive off the ring gear 4 Using the special tools remove the differential bearings 4221 if necessary 5 Remove the bolt and the differential pinion shaft 4211 6 WARNING Due to the spring tension use care when removing the differential ...

Page 422: ...ifferential side gears 4236 3 Remove the two differential pinion thrust washers 4230 8 CAUTION Keep the differential clutch packs 4947 in order Do not mix them Always reassemble them in the same sequence Separate the differential clutch packs and shims from the differential side gears and tag them right and left Clean and inspect the remaining differential components for wear and damage and instal...

Page 423: ...118 ml 4 oz of the specified Ford Friction Modifier must be used in the axle Lubricate each steel clutch plate and soak all friction plates for no less than 15 minutes Use Additive Friction Modifier C8AZ 19B546 A or equivalent meeting Ford specification EST M2C118 A 2 CAUTION Do not mix the differential clutch packs or shims from one side with the other Assemble the differential clutch packs witho...

Page 424: ...e Install the differential differential side gear and differential clutch pack without the shim on the tool 4 Position the special tool hand tight on top of the differential clutch pack 5 Install the special tool over the disc and differential clutch pack ...

Page 425: ...ess of the new clutch shim 8 Remove the special tools from the differential clutch pack and differential side gear assembly 9 Install shim s on the differential clutch pack and differential side gear assembly 10 Install the differential side gear assemblies in the differential case Selective Shims Part Number Description EOAZ 4A324 G 0 025 Inch EOAZ 4A324 H 0 030 Inch EOAZ 4A324 C 0 035 Inch EOAZ ...

Page 426: ...pinion gear and differential pinion thrust washer assemblies in the differential case 12 Using a soft faced hammer install the differential clutch spring 13 Install the differential pinion shaft and install a new bolt finger tight ...

Page 427: ...an the specification The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary 15 Using the special tool install the differential bearings if removed 16 Position the differential ring gear and the differential case Align the bolt holes by starting two bolts through the holes in the differential case and the differential ring gear Press the dif...

Page 428: ...Bearing Mount EOAZ 19554 BA or equivalent meeting Ford specification WSK M2G349 A1 to the bolt threads 18 Install the differential assembly in the differential housing For additional information refer to Differential Case in this section ...

Page 429: ...ttom of the fill hole Clearance Tolerance and Adjustments Maximum carrier spread 0 762 mm 0 030 in Maximum differential ring gear backface runout 0 076 mm 0 003 in Maximum differential case runout 0 076 mm 0 003 in Backlash between differential ring gear and pinion teeth 0 203 mm 0 008 in 0 330 mm 0 013 in Preferred backlash 0 254 mm 0 010 in Maximum backlash variation between teeth 0 1016 mm 0 00...

Page 430: ... Knuckle to lower suspension arm and bushing 115 85 Knuckle to upper suspension arm and bushing 90 66 Filler plug 34 25 Ring gear bolt a 105 77 Differential pinion shaft lock bolt 30 22 Bearing cap bolt 105 77 Differential housing cover bolt 32 24 Pinion bearing preload drive pinion collapsible spacer used bearings b 0 9 1 16 8 14 New pinion bearings 1 8 3 2 16 29 Traction Lok clutch gauge nut 6 7...

Page 431: ...anual Item Part Number Description 1 4067 Differential bearing shim 2 4222 Differential bearing cup 3 4204 Differential case 4 4216 Differential ring gear case bolt 5 4230 Differential pinion thrust washer 6 4211 Differential pinion shaft 7 4241 Differential pinion shaft lock bolt 8 Differential ring gear part of 4209 9 4221 Differential bearing ...

Page 432: ...ial bearing caps retain the differential assembly in the differential housing Inside the differential case the differential pinion shaft 4211 supports two differential pinion gears 4215 The pinion gears engage the differential side gears 4236 to which the halfshafts 10 4033 Differential housing cover 11 4B416 Inboard CV joint stub shaft pilot bearing housing seal 12 4B413 Inboard CV joint stub sha...

Page 433: ...aft in the differential case When installed the circlip engages a groove in the differential side gear The rear axle uses SAE 75W 140 High Performance Rear Axle Lubricant F1TZ 19580 B or equivalent meeting Ford specification WSL M2C192 A An embossed metal tag bolted to the differential housing cover contains rear axle identification For additional information refer to Section 205 00 ...

Page 434: ...efer to Section 205 05 2 NOTE If only removing the inboard CV joint stub shaft pilot bearing housing seal 4B416 SECTION 205 02C Rear Drive Axle Differential Ford 8 8 Inch IRS 2003 Mustang Workshop Manual Special Tool s Remover Bearing Cup 308 047 T77F 1102 A Protector Differential Seal Pair 205 461 Installer Differential Oil Seal 205 293 T89P 4850 A Adapter for 303 224 Handle 205 153 T80T 4000 W S...

Page 435: ...Inspect the seal journal for rust nicks and scratches Polish the seal journal with fine crocus cloth if necessary 2 Lubricate the new inboard CV joint stub shaft pilot bearing Use SAE 75W 140 High Performance Rear Axle Lubricant F1TZ 19580 B or equivalent meeting Ford specification WSL M2C192 A 3 CAUTION Installation without the correct tools can result in early bearing failure Place the inboard C...

Page 436: ...joint stub shaft pilot bearing housing seal becomes misaligned in the bore during installation remove it and install a new one Carefully align the inboard CV joint stub shaft pilot bearing housing seal in the housing bore and install the seal 8 CAUTION Use special tool 205 461 to avoid damaging the new inboard CV joint stub shaft pilot bearing housing seal when installing the halfshaft Install the...

Page 437: ......

Page 438: ...04 4 CAUTION Index mark the driveshaft flange and rear axle pinion flange 4851 to maintain initial balance during installation CAUTION The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot Never hammer on the driveshaft 4602 or any of its components to disconnect the yoke from the flange Pry only in the area shown with a suitable tool to disconnect the yoke from th...

Page 439: ...rive pinion gear through several revolutions 6 CAUTION After removing the nut discard it Use a new nut for installation Use the special tool to hold the rear axle pinion flange while removing the nut 7 Index mark the rear axle pinion flange and drive pinion gear stem to maintain initial balance during installation ...

Page 440: ...e seal journal with fine crocus cloth if necessary 2 Lubricate the rear axle pinion flange splines Use SAE 75W 140 High Performance Rear Axle Lubricant F1TZ 19580 B or equivalent meeting Ford specification WSL M2C192 A 3 NOTE Disregard the index marks if installing a new rear axle pinion flange Position the rear axle pinion flange 4 Using the special tools install the rear axle pinion flange ...

Page 441: ...reload recorded prior to disassembly is higher than the specification for used bearings then tighten the nut to the original reading as recorded Refer to the torque specification for used pinion bearings in the Specifications portion of this section 6 CAUTION Align the index marks CAUTION Install the driveshaft with new bolts If new bolts are not available apply Threadlock and Sealer EOAZ 19554 AA...

Page 442: ...7 Install the rear brake calipers For additional information refer to Section 206 04 8 Install the rear wheel and tire assemblies For additional information refer to Section 204 04 9 Lower the vehicle ...

Page 443: ...s and strike with a hammer to remove the seal Installation 1 Lubricate the new rear axle drive pinion seal Use Premium Long Life Grease XG 1 C or equivalent meeting Ford specification ESA M1C75 B 2 CAUTION Installation without the proper tool can result in early seal failure SECTION 205 02C Rear Drive Axle Differential Ford 8 8 Inch IRS 2003 Mustang Workshop Manual Special Tool s Installer Drive P...

Page 444: ... seal becomes misaligned during installation remove it and install a new one Using the special tool install the rear axle drive pinion seal 3 Install the pinion flange For additional information refer to Drive Pinion Flange in this section ...

Page 445: ...ve During installation raise the suspension to this reference mark before tightening the suspension component fasteners SECTION 205 02C Rear Drive Axle Differential Ford 8 8 Inch IRS 2003 Mustang Workshop Manual Special Tool s Plug Set Differential 205 294 T89P 4850 B Protector Differential Seal Pair 205 461 Remover Halfshaft 205 475 Remover Steering Arm 211 003 T64P 3590 F ...

Page 446: ...aft flange and rear axle pinion flange 4851 to maintain initial balance during installation CAUTION The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot Never hammer on the driveshaft 4602 or any of its components to disconnect the yoke from the flange Pry only in the area shown with a suitable tool to disconnect the yoke from the flange Disconnect and position th...

Page 447: ...ear brake disc For additional information refer to Section 206 04 Remove the rear brake caliper and support bracket from the knuckle as an assembly Wire the caliper and support bracket assembly out of the way 10 Remove the rear brake anti lock sensor and position it aside 11 Support the lower suspension arm and bushing with a jack stand 12 Remove and discard the nut and bolt 13 Remove and discard ...

Page 448: ...e special tool disconnect the toe link from the knuckle 15 Mark the cam bolt position relative to the upper suspension arm and bushing 16 Disconnect the knuckle from the lower suspension arm and bushing 1 Remove and discard the nut and bolt 2 Disconnect the knuckle from the lower suspension arm and bushing ...

Page 449: ...er suspension arm and bushing 18 CAUTION The crown on the tool forks must face away from the differential housing Position the special tool correctly between the CV joint and the differential housing so as not to damage the differential seal Using the special tool exert enough pressure to overcome the circlip and separate the CV joint from the differential side gear 19 Install the special tool 20 ...

Page 450: ...ol into the housing bore 22 Remove the other halfshaft and knuckle assembly as described in the previous steps 23 Support the differential housing 4010 with a transmission jack 24 Remove the bolts 25 Remove the nuts and bolts ...

Page 451: ...assembly from the vehicle 27 If removal of the mounting bushings is necessary remove them by hand Installation 1 Install the bushings if removed 2 Using the transmission jack raise the rear axle assembly into position 3 Install the bolts and nuts 4 Install the bolts ...

Page 452: ...riginal bolts CAUTION The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot To make sure that the yoke seats squarely on the flange tighten the bolts evenly in a cross pattern as shown Connect the driveshaft and install the bolts 6 Install the pinion nose crossmember 7 NOTE The following halfshaft and knuckle assembly installation steps apply to both sides of the v...

Page 453: ... shaft splines are past the differential seal 2 Remove the special tool 3 Align the stub shaft splines and the side gear splines and slide the stub shaft into the gear until it seats When seated the axle circlip will lock the stub shaft in the differential side gear Check the circlip engagement by attempting to pull the inboard CV joint out of the differential side gear If the circlip has not seat...

Page 454: ...he knuckle 2 Install the new cam bolt and nut 12 CAUTION Do not tighten the fastener at this time Connect the knuckle to the lower suspension arm and bushing 1 Position the knuckle 2 Install the new bolt and nut 13 Connect the toe link to the knuckle 1 Position the toe link 2 Install the new nut 3 Install the new cotter pin ...

Page 455: ...e of the lower suspension arm and bushing Position the shock absorber and install the bolt and the new nut 15 Install the other halfshaft and knuckle assembly toe link and shock absorber as described in the previous steps 16 Raise the suspension until the shock absorbers compress to the previously established alignment mark curb height 17 Tighten the nut ...

Page 456: ...ze Lubricant to the rear brake anti lock sensors where they contact the axle housing and install the anti lock sensors Use High Temperature Nickel Anti Seize Lubricant F6AZ 9L494 AA or equivalent meeting Ford specification ESE M12A4 A 22 Install the brake disc and the rear disc brake caliper and support bracket assembly For additional information refer to Section 206 04 23 Position the parking bra...

Page 457: ...refer to Section 204 04 28 CAUTION If refilling the rear axle 4001 first add 118 ml 4 oz of Additive Friction Modifier C8AZ 19B546 A or equivalent meeting Ford specification EST M2C118 A Check the lubricant level If necessary fill the rear axle housing to the level shown with SAE 75W 140 High Performance Rear Axle Lubricant F1TZ 19580 B or equivalent meeting Ford specification WSL M2C192 A The ref...

Page 458: ......

Page 459: ... 4221 A or equivalent Adapter for 205 S127 205 105 T76P 4020 A3 Bearing Preload Tool 205 395 T93P 4220 A Plate Bearing Oil Seal 205 090 T75L 1165 B Gauge Clutch Housing 308 021 T75L 4201 A Holding Fixture Drive Pinion Flange 205 126 T78P 4851 A Installer Drive Pinion Flange 205 002 TOOL 4858 E or equivalent Dial Indicator Gauge 100 D005 D78P 4201 G or equivalent ...

Page 460: ...1 TOOL 4000 E or equivalent Installer Differential Side Bearing 205 010 T57L 4221 A2 Adapter for 205 S127 205 110 T76P 4020 A10 Adapter for 205 S127 205 129 T79P 4020 A18 Gauge Tube Drive Pinion 205 336 T93P 4020 A Adapter for 205 S127 205 111 T76P 4020 A11 Spreader Differential Housing Plate 205 335 T93P 4000 A ...

Page 461: ...T53T 4621 C Installer Drive Pinion Bearing Cup 205 024 T67P 4616 A Protector Drive Pinion Thread 205 460 Installer Drive Pinion Oil Seal 205 133 T79P 4676 A Gauge Differential Bearing 205 339 T93P 4222 B Adapter for 205 S127 205 109 T76P 4020 A9 Step Plate 205 D061 D83T 4205 C2 or equivalent ...

Page 462: ... internal working parts and inspect the parts for wear and damage 3 Using the special tool measure and note the differential ring gear backface runout Remove the special tool Gauge Differential Clutch 205 135 T80P 4946 A Gauge Differential Clutch Torque 205 013 T59L 4204 A Remover Bearing 205 055 T71P 4621 B Holding Fixture Transmission 307 003 T57L 500 B ...

Page 463: ...r with two 3 8 inch x 1 1 2 inch bolts 5 Install the special tool by placing the spreader pins in the hole in the Housing Spreader Adapters 6 Assemble the special tool 1 Install the special tool 2 Attach the special tool and position the tip in the Housing Spreader Adapter hole 7 CAUTION Overspreading can damage the differential housing NOTE Tighten and loosen the Differential Carrier Spreader scr...

Page 464: ...cal location and position Remove the differential bearing caps 1 Remove the bolts 2 Remove the differential bearing caps 9 CAUTION Use wood blocks to avoid damaging the differential housing Remove the differential assembly 1 Position wood blocks at the top and bottom of the differential case 4204 2 Pry the differential assembly and the differential bearing shims 4067 out of the differential housin...

Page 465: ...n seal metal flange up and strike it with a hammer 12 Using gripping pliers and a hammer remove the rear axle drive pinion seal 4676 13 Remove the rear axle drive pinion shaft oil slinger 4670 14 Using the special tool and a soft faced hammer drive the drive pinion gear out of the front pinion bearing 4621 and remove it through the rear of the differential housing 15 Remove and discard the differe...

Page 466: ...nion bearing adjustment shim thickness Use this measurement as a reference to compare to the shim gauge reading taken prior to installing the pinion bearing Remove the drive pinion bearing adjustment shim 4663 18 Using a brass drift and a hammer remove any damaged differential drive pinion bearing cup 4616 4628 from the differential housing Tap alternately on each side of the cup to prevent it fro...

Page 467: ...l ring gear a damaged differential case or loss of differential bearing preload Proceed to Excessive differential ring gear backface runout in this procedure to verify the cause of the excessive runout Excessive differential ring gear backface runout 20 Place the differential assembly with the differential bearings 4221 and the differential bearing cups 4222 in the differential housing 21 Install ...

Page 468: ...essively larger differential bearing shims on the RH side until the largest differential bearing shim selected can be assembled with a slight drag feel 24 Install the RH differential bearing cap Tighten both bearing caps to specification 25 Rotate the differential assembly to make sure it turns freely ...

Page 469: ...sive runout was due to a loss of differential bearing preload Proceed to Final disassembly in this procedure If the runout exceeds the specification proceed as follows Remove the special tool 27 Remove the differential assembly 28 Remove the bolts 29 CAUTION Do not damage the bolt hole threads Insert a punch in the bolt holes and drive off the differential ring gear ...

Page 470: ...the differential case Discard the differential ring gear and the drive pinion gear Proceed to Final disassembly in this procedure If the runout exceeds the specification the differential ring gear is true and the concern is due to either differential case differential bearing damage Remove the differential case Discard the differential bearings differential case Proceed to Final disassembly in thi...

Page 471: ... If not done previously insert a punch in the bolt holes and drive off the differential ring gear 34 Using the special tools remove the differential bearing Repeat for the other side 35 Remove the bolt and remove the differential pinion shaft 4211 ...

Page 472: ...nion gears 4215 and pinion thrust washers 4230 2 Remove the two differential side gears 4236 with the clutch packs 4947 and the shims and tag them left and right 38 CAUTION Keep the differential clutch packs in order Do not mix them Always reassemble them in the same sequence Remove the differential clutch packs and shims from the differential side gears Clean and inspect the remaining differentia...

Page 473: ...gh Performance Rear Axle Lubricant F1TZ 19580 B or equivalent meeting Ford specification WSL M2C192 A 2 Using the special tool install the differential drive pinion bearing cup s 1 Position the bearing cup s on the special tool 2 Position the special tool and the bearing cup s in the differential housing 3 Tighten the special tool to fully seat the bearing cup s in the bore s 3 NOTE Apply a light ...

Page 474: ... and tighten to the specification shown 5 CAUTION Offset the special tool to obtain an accurate reading Item Part Number Description 1 205 109 Adapter for 205 S127 2 205 105 Adapter for 205 S127 3 4630 Rear inner pinion bearing 4 205 129 Adapter for 205 S127 5 205 110 Adapter for 205 S127 6 4621 Front outer pinion bearing 7 205 111 Adapter for 205 S127 ...

Page 475: ...bearing adjustment shim thickness between the Gauge Block and the Gauge Tube A slight drag indicates correct shim selection 8 Remove all of the special tools 9 CAUTION Use the same pinion bearings and drive pinion bearing adjustment shim from the drive pinion bearing adjustment shim selection procedure for final assembly Position the drive pinion bearing adjustment shim and the pinion bearing on t...

Page 476: ...mium Long Life Grease XG 1 C or equivalent meeting Ford specification ESA M1C75 B Using the special tool install the new rear axle drive pinion seal 13 CAUTION Make sure the splines on the drive pinion gear stem are free of burrs If burrs are evident remove them using a fine crocus cloth work in a rotational motion Place a new differential drive pinion collapsible spacer on the drive pinion gear s...

Page 477: ...al tool install the rear axle pinion flange 17 CAUTION Do not under any circumstance loosen the nut to reduce preload If it is necessary to reduce preload install a new differential drive pinion collapsible spacer and nut Tighten the nut to set the preload Rotate the pinion occasionally to make sure the pinion bearings seat correctly Take frequent pinion bearing torque preload readings by rotating...

Page 478: ... specification for used bearings then tighten the nut to the original reading as recorded 18 CAUTION 118 ml 4 oz of Additive Friction Modifier C8AZ 19B546 A or equivalent meeting Ford specification EST M2C118 A must be used in the axle Lubricate each steel clutch plate and soak all friction plates for no less than 15 minutes Use Additive Friction Modifier C8AZ 19B546 A or equivalent meeting Ford s...

Page 479: ...portion of the special tool in a vise 21 Install the differential clutch pack and differential side gear without the shim on the special tool 22 Position the special tool hand tight on top of the differential clutch pack ...

Page 480: ...he thickest feeler gauge blade that will enter between the tool and the differential clutch pack The reading will be the thickness of the new clutch shim Selective Shims Part Number Description EOAZ 4A324 G 0 025 Inch EOAZ 4A324 H 0 030 Inch EOAZ 4A324 C 0 035 Inch EOAZ 4A324 D 0 040 Inch EOAZ 4A324 F 0 045 Inch ...

Page 481: ...n the differential clutch pack and differential side gear assembly 28 Install the differential side gear assemblies in the differential case 29 Install the differential pinion gear and differential pinion thrust washer assemblies in the differential case 30 Using a soft faced hammer install the differential clutch spring ...

Page 482: ...erential case and the special tool in a vise Using the special tool check the torque necessary to rotate one differential side gear If reusing the original clutch plates the initial minimum break away torque must be no less than the specification The minimum rotating torque necessary to keep the differential side gear turning with new clutch plates may vary 33 CAUTION The Master bearings are marke...

Page 483: ...lay 1 Attach the special tool and position the indicator tip on the machined surface of the differential case flange 2 Move the differential case to the left and the right as far as possible 3 Record the reading on the differential bearing shim selection procedure line A Differential Bearing Shim Selection Chart 8 8 inch Aluminum Axle Example Actual Line A End play without ring gear 0 498 Line B E...

Page 484: ...le Actual Master bearing height 0 8695 0 8695 0 8695 0 8695 Line D Actual bearing height 0 8478 Minus 0 8491 Minus Line E Difference 0 0217 0 0204 8 8 inch Aluminum Axle Left Side 8 8 inch Aluminum Axle Right Side Example Actual Example Actual Line B End play Line E Bearing height 0 2450 0 0217 Line C End play Line E Bearing height 0 2530 0 0204 TOTAL Lines B and E Backlash subtract 0 2667 0 0060 ...

Page 485: ...e differential ring gear and the differential case 3 Place the differential case and differential ring gear onto the press bed blocks with the differential ring gear teeth facing downward 4 Press the differential ring gear into place 40 Install the remaining bolts 41 Place the differential case with the special tools into the differential housing ...

Page 486: ...sh set the special tool to zero 4 Move the differential case as far as possible to the left and note the reading 5 Record the reading on the differential bearing shim selection procedure line B Remove the special tool 43 Remove the differential case from the differential housing 44 Remove the bolts Apply Stud and Bearing Mount EOAZ 19554 BA or equivalent meeting Ford specification WSK M2G349 A1 to...

Page 487: ...n the bolt 46 Measure the differential bearing stand height 1 Invert the special tool and clamp the bolt head in a vise 2 Position a depth micrometer flat on the differential bearing 47 Measure both differential bearings stand height Record the measurement on the differential bearing shim selection procedure line D 48 Press the left and right differential bearing on the differential case 49 Instal...

Page 488: ...pecification 3 Remove the special tools 51 NOTE Select the correct size differential bearing shims by completing the differential bearing shim selection chart NOTE Apply a light coating of Premium Long Life Grease XG 1 C or equivalent meeting Ford specification ESA M1C75 B to the differential bearing shim to help hold in place Place the differential bearing shims in the differential housing 52 Ins...

Page 489: ...the differential bearing caps in their original locations and positions and tighten the bolts 54 Remove the special tool 55 Install the special tool at the 12 o clock position 56 Using the special tools measure the differential ring gear backlash at four equally spaced points ...

Page 490: ...ocedure To correct for a high or low backlash proceed as follows 57 To correct for high or low backlash increase the thickness of one differential bearing shim and decrease the thickness of the other differential bearing shim by the same amount Refer to the following tables when adjusting the backlash When the backlash is within specifications proceed to Final assembly in this procedure Backlash C...

Page 491: ...2850 0 2855 5 GRN 7 1882 7 2009 0 2830 0 2835 4 GRN 7 1374 7 1501 0 2810 0 2815 3 GRN 7 0866 7 0993 0 2790 0 2795 2 GRN 7 0358 7 0485 0 2770 0 2775 1 GRN 6 9850 7 0485 0 2750 0 2755 5 WH 6 9342 6 9469 0 2730 0 2735 4 WH 6 8834 6 8961 0 2710 0 2715 3 WH 6 8326 6 8453 0 2690 0 2695 2 WH 6 7818 6 7945 0 2670 0 2675 1 WH 6 7310 6 7437 0 2650 0 2655 5 YEL 6 6802 6 6929 0 2630 0 2635 4 YEL 6 6294 6 6421...

Page 492: ...or one hour before filling the axle with lubricant Apply a continuous bead of sealant of the specified thickness to the differential housing cover mounting surface Use Clear Silicone Rubber F7AZ 19554 CA or equivalent meeting Ford specification ESB M4G92 A 59 Install the differential housing cover 60 CAUTION First fill the rear axle 4001 with 118 ml 4 oz of Additive Friction Modifier C8AZ 19B546 A...

Page 493: ......

Page 494: ...Item Specification Halfshaft assembled length 817 6 mm 32 19 in Torque Specifications Description Nm lb ft Tie rod end to knuckle 47 35 Shock absorber to suspension lower arm 133 98 Suspension upper arm and bushing to knuckle 90 66 Rear brake anti lock sensor bolt 7 5 Rear axle wheel hub retainer 325 240 ...

Page 495: ...ints have a higher angle capability than the inboard CV joints to accommodate suspension travel Inboard and outboard CV joints connect to a splined shaft A driveshaft bearing retainer circlip retains the splined inboard CV joint to the differential side gear Install a new circlip every time you remove the halfshaft from the vehicle A rear axle wheel hub retainer secures the interconnecting shaft a...

Page 496: ...y as a lever to position other components Always support the free end of the halfshaft Do not allow the boots to contact sharp edges or hot exhaust components Item Part Number Description 1 4B422 Driveshaft bearing retainer circlip 2 2C189 Rear brake anti lock sensor indicator 3 Retaining ring part of 4B402 4 4B478 Boot clamp large inboard 5 Rear axle shaft inner boot part of 4B402 6 4B478 Boot cl...

Page 497: ...ntial or halfshaft failure can result causing personal injury or extensive component damage Use an off vehicle wheel and tire balancer only Hoisting CAUTION Use a frame contact hoist only Vehicle or component damage can result if other types of hoists are used Never raise the vehicle using the halfshafts as lift points Undercoating and Rustproofing During undercoating and rustproofing procedures p...

Page 498: ... protective sleeve During installation raise the suspension to this reference mark before tightening the suspension component fasteners SECTION 205 05 Rear Drive Halfshafts 2003 Mustang Workshop Manual Special Tool s Differential Plug 205 294 T89P 4850 B Differential Seal Protector 205 461 Front Hub Remover 205 D070 D93P 1175 B or Equivalent Halfshaft Removal Tool 205 475 Steering Arm Remover 211 ...

Page 499: ...l information refer to Section 204 04 4 Remove and discard the rear axle wheel hub retainer 5 Remove the rear brake disc For additional information refer to Section 206 04 6 Remove the rear brake anti lock sensor and position aside 7 Support the suspension lower arm and bushing This will ease removal of the lower shock absorber mount bolt ...

Page 500: ... arm and bushing Discard the nut and the bolt 9 Remove and discard the cotter pin and the nut 10 Using the special tool disconnect the tie rod link at the knuckle 11 Disconnect the suspension upper arm and bushing at the knuckle Discard the nut and the bolt ...

Page 501: ...n on the tool forks must face away from the axle housing Position the special tool correctly between the CV joint and the axle housing so as not to damage the differential seal Using the special tool exert enough pressure to overcome the circlip and separate the CV joint 4K326 from the differential side gear 15 CAUTION Do not damage the differential seal Carefully remove the halfshaft 4K138 with b...

Page 502: ... to both the LH and RH halfshafts Install a new driveshaft bearing retainer circlip 2 Remove the special tool 3 CAUTION Differential seal damage will occur if installing the halfshaft without the special tool installed Install the special tool ...

Page 503: ... seats When seated the axle circlip will lock the stub shaft in the differential side gear Check the circlip engagement by attempting to pull the inboard CV joint out of the differential side gear If the circlip has not seated push the CV joint inward until the circlip is fully engaged in the differential side gear 6 Connect the axle shaft to the hub 1 Making sure the serrations on the shaft line ...

Page 504: ...e 2 Install the new bolt and a new nut Do not tighten the nut at this time 8 Connect the tie rod end to the knuckle 1 Position the tie rod link in the knuckle 2 Install a new nut 3 Install a new cotter pin 9 Raise the suspension until the shock absorber is compressed to the previously established alignment mark curb height ...

Page 505: ...e jack stand 13 Apply Anti Seize Lubricant to the rear brake anti lock sensor where it contacts the axle housing and install the anti lock sensor Use High Temperature Nickel Anti Seize Lubricant F6AZ 9L494 AA or equivalent meeting Ford specification ESE M124A A 14 Install the rear brake disc For additional information refer to Section 206 04 15 Tighten the retainer ...

Page 506: ...nstall the wheel and tire assembly For additional information refer to Section 204 04 17 Lower the vehicle 18 Check the wheel alignment Adjust as necessary For additional information refer to Section 204 00 ...

Page 507: ...n 2 If necessary remove the dust seal assembly 2217 1 Tap uniformly around the dust seal assembly 2 Slide the dust seal assembly from the shaft 3 Using a suitable bearing plate and a press remove the rear brake anti lock sensor indicator if necessary SECTION 205 05 Rear Drive Halfshafts 2003 Mustang Workshop Manual Special Tool s Driver 205 199 T83T 3132 A1 Hub Bearing Cup Replacer 205 147 T80T 40...

Page 508: ... the bearing plate Do not press against any other portion of the outer race or damage will occur If removed using the special tools the bearing plate and a suitable press seat the rear brake anti lock sensor indicator against the inboard CV joint housing 3 Install the halfshaft in the vehicle For additional information refer to Halfshaft in this section ...

Page 509: ......

Page 510: ...ustang Workshop Manual Torque Specifications Description Nm lb ft lb in Front disc brake caliper bleeder screw 12 18 9 13 Front master cylinder brake tube 22 28 17 20 Rear bleeder screw 20 15 Rear master cylinder brake tube 15 20 11 14 Master cylinder bleeder screws 9 80 ...

Page 511: ...IPTION AND OPERATION Brake System Component Locations SECTION 206 00 Brake System General Information 2003 Mustang Workshop Manual Item Part Number Description 1 2C346 Four wheel anti lock brake system 4WABS ...

Page 512: ...dent hand operated parking brake control and is self adjusting Refer to Section 206 05 A 4 wheel anti lock brake system or anti lock brake system with traction control 4WABS is optional equipment on all models except Cobra Cobra has ABS and traction control as standard equipment Refer to Section 206 09A hydraulic control unit and control module assy non traction 1 2C353 Four wheel anti lock brake ...

Page 513: ...ll brake fluid onto painted surfaces If spilled wipe up immediately NOTE Always check the fluid level in the brake master cylinder reservoir 2K478 before performing the test procedures If the fluid level is not at the correct level add High Performance DOT 3 Brake Fluid C6AZ 19542 AB or equivalent DOT 3 fluid meeting Ford specification ESA M6C25 A NOTE Prior to performing any diagnosis make sure t...

Page 514: ...rommets are not separately serviceable and must be installed new as part of a new brake master cylinder reservoir Install a new flexible brake hose if it shows signs of softening cracking or other damage When installing a new brake hose position the hose to avoid contact with other vehicle components Road Test Perform a road test to compare actual vehicle braking performance with the performance s...

Page 515: ...ns when brakes are applied perform the following procedure Visually inspect tire condition and pressure suspension bushings and ball joints Correct as necessary 1 Verify and isolate the concern Brake roughness can be felt in the steering wheel the seat the brake pedal 2 After verifying the concern check for related concerns in the On Line Automotive Service Information System OASIS Technical Servi...

Page 516: ...indicator verify that the brake disc lateral runout is now within vehicle specification 10 Remove any metal chips 11 Remove the hub adapter 12 Remove any remaining metal chips from the machining operation 13 CAUTION Do not carry out this step on rear drum in hat brake discs For vehicles with a two piece hub and a non drum in hat brake disc assembly Remove the brake disc from the hub Remove any rem...

Page 517: ...rake control system Go To Pinpoint Test C Excessive Erratic Brake Pedal Travel Leak in hydraulic system Air in system Disc brake caliper Brake master cylinder Go To Pinpoint Test D Brakes Drag Parking brake component REPAIR or INSTALL new components as necessary REFER to Section 206 05 Disc brake caliper REPAIR or INSTALL a new brake caliper as necessary REFER to Section 206 03 and Section 206 04 ...

Page 518: ...ro Boost Erratic Operation Sticks Binds or Grabs Supply hose Hydro boost unit Go To Pinpoint Test F Hydro Boost Brake System Operation Suspect Leakage Hydro boost unit Go To Pinpoint Test G Test Step Result Action to Take A1 CHECK THE TIRES NOTE Check tire pressure with the brakes off Check tires for uneven and excessive wear and for correct pressure Are the tires OK Yes GO to A2 No CORRECT as nec...

Page 519: ...er the drift occurs with or without the brakes applied Does the drift or pull occur with the brakes applied Yes REPAIR or INSTALL new front disc brake caliper or anchor plate guide pins on the side opposite to the direction of the drift or pull No REPAIR or INSTALL new front disc brake caliper or anchor plate guide pins on the side of the vehicle in the direction of the drift or pull Test Step Res...

Page 520: ...nce greater than 10 000 ohms Yes REPAIR the GEM TEST the system for normal operation No For vehicles without Daytime Running Lights DRL GO to B4 For vehicles with DRL GO to B5 B4 CHECK CIRCUITS 977 VT WH 22 LB BK AND 128 VT YE Remove the fused jumper from C124 Measure the resistance to ground at C124 2 Is the resistance greater than 10 000 ohms Yes REPAIR the ground short in circuit 128 VT YE TEST...

Page 521: ...1 INSPECT THE TIRES Inspect the tires for uneven or excessive wear correct pressure correct size and type Are the tires OK Yes GO to C2 No CORRECT as necessary RETEST for normal operation C2 CHECK THE BRAKE CALIPER COMPONENTS Inspect the brake pads and brake discs for wear damage contamination and correct installation Are the brake components OK Yes GO to C3 No CORRECT as necessary RETEST for norm...

Page 522: ...nd anti rattle springs for binding damage contamination and correct installation Are the bolts and springs OK Yes GO to D4 No REPAIR or INSTALL new components as necessary RETEST for normal operation D4 CHECK THE BOOSTER AND MASTER CYLINDER Check the power brake booster and brake master cylinder for correct installation and correct push rod adjustment Refer to Section 206 06 and to Section 206 07 ...

Page 523: ...ING PUMP SPEED Check engine idle speed against specifications Is engine idle speed OK Yes GO to E6 No SET engine idle speed to specification REFER to Powertrain Control Emissions Diagnosis PC ED manual E6 CHECK FOR PLUGGED RETURN HOSE NOTE The return hose from the oil cooler to the power steering reservoir has an in line filter in the hose Disconnect power steering return hose from power steering ...

Page 524: ... Does the brake pedal fall slightly and hold and is less pressure now required to hold brake pedal at the new position Yes Hydro boost is OK No GO to G2 G2 CHECK FOR HYDRAULIC BRAKE LEAK With engine running press and release brake pedal several times Hold brake pedal down with medium pressure 34 47 Nm 25 35 lb ft Does brake pedal move toward floor Yes GO to G3 No GO to G4 G3 CHECK FOR LEAKS BRAKE ...

Page 525: ...let the vehicle stand for 10 minutes Then apply the brake pedal with approximately 89 N 20 lb of force The brake pedal feel should be the same as that noted with the engine operating If the brake pedal feels hard no power assist install a new power brake booster check valve and retest If the brake pedal feels spongy bleed the hydraulic system to remove air For additional information refer to Bleed...

Page 526: ...net fluid level i e after brake application and release will remain unchanged Condition 2 A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange This results from the normal lubricating action of the master cylinder bore and seal Condition 3 Fluid level will decrease with pad wear Brake Master Cylinder Abnormal Conditions Changes in brake pedal feel or tra...

Page 527: ...Turbulence seen in the brake master cylinder reservoir upon application or release of the brake pedal is normal and shows that the compensating ports are not plugged ...

Page 528: ...stic surfaces If brake fluid is spilled onto a painted or plastic surface immediately wash it with water NOTE When any part of the hydraulic system has been disconnected for repair or installation of new components air can enter the system and cause spongy brake pedal 2455 action This requires bleeding of the hydraulic system after it has been correctly connected The hydraulic system can be bled m...

Page 529: ...ake Fluid C6AZ 19542 AB or equivalent DOT 3 fluid meeting Ford specification ESA M6C25 A 4 Have an assistant pump the brake pedal 2455 or slowly depress the primary piston until clear fluid flows from both brake tubes without air bubbles 5 If the brake master cylinder has been primed at the bench install it in the vehicle For additional information refer to Section 206 06 6 Remove the short brake ...

Page 530: ...Priming 4 6L 1 CAUTION Use only bleed screws on the engine side of the brake master cylinder 2140 The hydro boost bleed screw located near the dash on the hydro booster casting is for the booster cavity filled with power steering fluid not brake fluid Connect a clear waste line to the bleed screw closet to the booster first and the other end in a container partially filled with recommended brake f...

Page 531: ... cylinder reservoir 2K478 with the specified brake fluid 2 Connect a clear waste line to the RH rear bleeder screw 2208 and the other end in a container partially filled with recommended brake fluid 3 Loosen the RH rear bleeder screw until a stream of brake fluid comes out While the assistant maintains pressure on the brake pedal 2455 tighten the RH rear bleeder screw Repeat until clear bubble fre...

Page 532: ... dash and follow the scan tool instructions 7 Repeat the system bleed procedure as outlined in Steps 1 through 5 Caliper 1 NOTE It is not necessary to do a complete brake system bleed if only the disc brake caliper 2B120 was disconnected Place a box end wrench on the disc brake caliper bleeder screw 2208 Attach a rubber drain tube to the disc brake caliper bleeder screw and submerge the free end o...

Page 533: ...eder screw until a stream of brake fluid comes out While the assistant maintains pressure on the brake pedal tighten the disc brake caliper bleeder screw Repeat until clear bubble free fluid comes out Refill the brake master cylinder reservoir 2K478 as necessary 4 Tighten the disc brake caliper bleeder screw Refer to Specifications ...

Page 534: ... plastic surfaces If brake fluid is spilled onto a painted or plastic surface immediately wash it with water NOTE When any part of the hydraulic system has been disconnected for repair or installation of new components air can get into the system and cause spongy brake pedal action This requires bleeding of the hydraulic system after it has been correctly connected The hydraulic system can be bled...

Page 535: ...per bleeder screw Attach a rubber drain tube to the RH front disc brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid 8 Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal 9 Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out While the assistant maintains ...

Page 536: ...the instructions of the manufacturer when installing the adapter Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter 3 NOTE Bleed the longest line first Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation Place a box end wrench on the RH rear bleeder screw Attach a rubber d...

Page 537: ... screw and remove the rubber hose 6 Continue bleeding the rear of the system going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw 7 Close the bleeder tank valve Remove the tank hose from the adapter and remove the adapter ...

Page 538: ...ke master cylinder reservoir 2K478 is full 2 Apply the brakes several times and make sure the brake pedal 2455 feel is not spongy If necessary bleed the system For additional information refer to Bleeding System in this section 3 If the reservoir level is dropping inspect the brake components fittings and lines to locate the source of the leak SECTION 206 00 Brake System General Information 2003 M...

Page 539: ...le the Brake Measurement Kit using the spherical tip extension 4 Locate an opening on the inboard side of the dust shield that will allow the dial indicator tip to be positioned at least 5 mm 0 2 inch from the outer edge of the brake disc 5 NOTE Do not clamp the gauge set to a vehicle component separated from the brake disc by a flexible joint such as a ball joint or body mount Clamp the Brake Mea...

Page 540: ...dicated runout exceeds the maximum specification For additional information refer to Section 204 01 Repeat the hub runout measurement 11 NOTE Clean the axle flange surface before measuring NOTE For rear wheels press inward on the axle shaft while measuring the rear axle runout For rear wheels measure and record the total indicated runout at a point on the axle shaft outside the stud circle 12 If t...

Page 541: ...isc to the runout specification go to Step 14 If the thickness is not sufficient install a new brake disc and recheck the TIR 14 NOTE Brake disc machining must be done with an on vehicle lathe Follow the lathe manufacturer s instructions Machine the brake disc if final thickness will not be less than the maximum specification Recheck the brake disc runout ...

Page 542: ...Disc thickness Mustang Mustang Cobra 26 mm 1 02 in 28 mm 1 10 in Disc lateral runout 0 05 mm 0 002 in Disc thickness variation 0 009 mm 0 00035 in Hub runout 0 025 mm 0 001 in Torque Specifications Description Nm lb ft Disc brake caliper bolt 31 23 Front brake hose bolt 40 30 Front disc brake caliper anchor plate bolt 115 85 Disc brake caliper bleeder screw 10 7 ...

Page 543: ...t Disc Brake 2003 Mustang Workshop Manual Item Part Number Description 1 Bleeder screw and bleeder screw cap assy 2 2N386 Caliper bolt 3 2B296 Guide pin 4 2A492 Guide pin boot 5 2B120 Disc brake caliper 6 2B164 Anti rattle spring 7 2B292 Front disc brake caliper anchor plate 8 385116 S2 Flow bolt 9 2078 Front brake hose ...

Page 544: ...are serviced with the disc brake caliper and front disc brake caliper anchor plate removed The front brake disc shield 2K005 Item Part Number Description 1 2B120 Disc brake caliper 2 2L126 Bleeder screw cap 3 2208 Bleeder screw 4 2B164 Anti rattle spring 5 2196 Caliper piston 6 2B115 Piston seal 7 2207 Piston dust boot 8 2L200 Pad slipper 9 2B292 Front disc brake caliper anchor plate 10 2001 Brake...

Page 545: ... the front wheel spindle protects the front wheel bearings and inboard surface of the front brake disc The pads are housed in the front disc brake caliper anchor plate are of a non asbestos non metallic composition ...

Page 546: ...mation refer to Section 100 02 3 Remove the wheel and tire assembly For additional information refer to Section 204 04 4 CAUTION Install new pads if worn to or past the specified thickness above the metal backing plate or rivets Install pads in complete axle sets Inspect the pads for wear and contamination 5 Remove the caliper bolts 1 Hold the guide pins stationary 2 Remove and discard the caliper...

Page 547: ...stons and boots CAUTION When removing the disc brake caliper 2B120 never allow it to hang from the brake hose Provide a suitable support Lift the caliper off the anchor plate 2B292 7 Remove the pads and the pad slippers 1 Remove the pads and verify thickness 2 Remove and discard slippers ...

Page 548: ...sc thickness Install a new front brake disc 1125 if not within specification 9 Inspect the disc brake caliper If leaks or damaged boots are found disassembly is required For additional information refer to Caliper in this section ...

Page 549: ...ng and damage Worn or damaged pins should be installed new Installation 1 CAUTION Do not allow grease oil brake fluid or other contaminants to contact the pad lining material Do not install contaminated pads NOTE Install all hardware supplied with pad kits Install the pads 1 Install the new pad slippers 2 Install the pads ...

Page 550: ...2 NOTE Use a wood block or used pad to protect pistons and boots Compress the caliper pistons 2196 3 Make sure the anti rattle spring is correctly positioned in the caliper ...

Page 551: ...caliper bolts 5 Install the wheel and tire assembly For additional information refer to Section 204 04 6 Lower the vehicle 7 Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ 19542 AB or equivalent DOT 3 fluid meeting Ford specification ESA M6C25 A Install brake master cylinder filler cap 8 Inspect brake operation ...

Page 552: ......

Page 553: ...02 3 Remove the tire and wheel assembly For additional information refer to Section 204 04 4 CAUTION Install new pads if worn to or past the specified thickness above the metal backing plate or rivets Install new pads in complete axle sets Inspect the pads for wear and contamination 5 Remove the caliper locating pin E clip 6 Remove the caliper locating pin SECTION 206 03 Front Disc Brake 2003 Must...

Page 554: ...7 Remove the caliper 8 Remove the brake pads 9 Measure the brake disc thickness Install a new brake disc if not within specification ...

Page 555: ...caliper If leaks or damaged boots are found disassembly is required For additional information refer to Caliper in this section 11 NOTE Use a wood block or used pad to protect pistons and boots Compress the caliper pistons 2196 ...

Page 556: ...Installation 1 Follow the removal procedure in reverse order ...

Page 557: ...utes get medical attention if irritation persists If taken internally drink water and induce vomiting Get medical attention immediately CAUTION Brake fluid is harmful to painted and plastic surfaces If brake fluid is spilled onto a painted or plastic surface wash it with water immediately Disconnect the front brake hose 2078 1 Remove the front brake flow bolt 2 Disconnect the front brake hose 3 Re...

Page 558: ...292 6 Inspect the disc brake caliper If leaks or damaged boots are found disassembly is required For additional information refer to Caliper in this section Installation 1 Make sure the anti rattle spring is correctly positioned in the caliper ...

Page 559: ...guide pin boots are correctly seated or damage to guide pins can occur Install the disc brake caliper 1 Hold the guide pins stationary 2 Install the caliper bolts 3 NOTE Use new copper washers Install the front brake hose ...

Page 560: ...ly For additional information refer to Section 204 04 6 Fill the brake master cylinder reservoir 2K478 with clean High Performance DOT 3 Brake Fluid C6AZ 19542 AB or equivalent DOT 3 fluid meeting Ford specification ESA M6C25 A Install brake master cylinder filler cap 2162 7 Check the brake system operation ...

Page 561: ...tion refer to Section 100 02 2 Remove the tire and wheel assembly For additional information refer to Section 204 04 3 Remove the caliper locating pin E clip 4 Remove the caliper locating pin 5 Remove the front brake flow bolt 6 Remove the caliper SECTION 206 03 Front Disc Brake 2003 Mustang Workshop Manual ...

Page 562: ...Remove the brake pads Installation 1 NOTE Use new copper washers on front brake flow bolt Follow the removal procedure in reverse order Bleed the caliper For additional information refer to Section 206 00 ...

Page 563: ......

Page 564: ...Cobra Removal 1 Remove the pads For additional information refer to Brake Pads Cobra in this section 2 Remove the anchor plate bolts Installation 1 Follow the removal procedure in reverse order SECTION 206 03 Front Disc Brake 2003 Mustang Workshop Manual ...

Page 565: ......

Page 566: ...ads in this section 2 Remove the anchor plate 2B292 1 Remove and discard the anchor plate bolts 2 Remove the anchor plate Installation 1 CAUTION Use correct type and length bolts Follow the removal procedure in reverse order Install new anchor plate bolts SECTION 206 03 Front Disc Brake 2003 Mustang Workshop Manual ...

Page 567: ......

Page 568: ...Penetrant and Inhibitor F2AZ 19A501 A or equivalent meeting Ford specification ESR M99C56 A to the mating surfaces Remove the brake disc from the hub Installation 1 Clean rust and foreign material from the mating surfaces of the hub and brake disc Use Metal Brake Parts Cleaner F3AZ 19579 SA or equivalent to clean the brake disc and hub 2 Apply High Temperature Nickel Anti Seize Lubricant F6AZ 9L49...

Page 569: ...nd install the brake disc 4 Install the anchor plate 2B292 For additional information refer to Brake Caliper Anchor Plate in this section 5 Check the total indicated runout TIR For additional information refer to Section 206 00 ...

Page 570: ...he brake disc shield 2K004 1 Drill out three brake disc shield rivets 2 Remove the brake disc shield Installation 1 Install the brake disc shield 1 Position the shield 2 Secure with three rivets 2 Install the brake disc For additional information refer to Disc in this section SECTION 206 03 Front Disc Brake 2003 Mustang Workshop Manual ...

Page 571: ......

Page 572: ...fluid port in the disc brake caliper 1 Place a block of wood between the caliper bridge and the caliper pistons 2196 2 Apply low air pressure to the fluid port in the disc brake caliper and force out the caliper pistons to the block of wood 4 Remove the caliper pistons 1 Remove the block of wood 2 Remove the caliper pistons 5 Remove and discard the piston seals and boots SECTION 206 03 Front Disc ...

Page 573: ...caliper Remove dirt and debris Examine the caliper pistons for surface irregularities scoring or wear Damaged caliper pistons should be installed new Clean the caliper bores with Metal Brake Parts Cleaner F3AZ 19579 SA or equivalent meeting Ford specification If the caliper bores are corroded or excessively scored install a new disc brake caliper Lubricate the caliper pistons and piston seals befo...

Page 574: ... hydraulic system or has been allowed to stand in an open container for an extended period of time Lubricate the caliper piston piston seal and caliper bores with clean High Performance DOT 3 Brake Fluid C6AZ 19542 AB or equivalent DOT 3 fluid meeting Ford specification ESA M6C25 A 3 Install the caliper piston ...

Page 575: ... not to damage or dislodge the piston seal Insert the caliper piston 4 CAUTION Be careful not to cock the caliper piston Press the caliper piston into the bore 4 Install a new bleed screw and cap 5 Install the disc brake caliper For additional information refer to Caliper in this section ...

Page 576: ......

Page 577: ...040 in Disc thickness 15 mm 0 59 in Disc lateral runout 0 102 mm 0 004 in Disc thickness variation 0 01 mm 0 0004 in Hub runout Torque Specifications Description Nm lb ft lb in Rear wheel brake hose to rear disc brake caliper retaining bolt 40 30 Rear disc brake support bracket bolts 103 76 Brake disc shield bolts 9 12 80 106 Rear brake pin retainer 33 25 ...

Page 578: ...ediately The rear disc brake system consists of solid full cast brake disc 2C026 hydraulically activated rear disc brake caliper 2552 integral mechanically cable operated parking brake mechanism that is self adjusting Rear Disc Brake System Components SECTION 206 04 Rear Disc Brake 2003 Mustang Workshop Manual Item Part Number Description 1 2552 Rear disc brake caliper 2 2C028 Brake disc shield 3 ...

Page 579: ......

Page 580: ...e assembly For additional information refer to Section 204 04 3 Disengage the parking brake cable end from the parking brake lever arm 4 Remove the parking brake cable retaining clip 5 Remove the parking brake cable and conduit SECTION 206 04 Rear Disc Brake 2003 Mustang Workshop Manual Special Tool s Rear Caliper Piston Adjuster 206 026 T87P 2588 A ...

Page 581: ...ke hose bolt 7 Remove the rear brake pin retainers 2N386 and remove the caliper Installation 1 NOTE Use new copper washers Follow the removal procedure in reverse order Bleed the brake system For additional information refer to Section 206 00 ...

Page 582: ......

Page 583: ... additional information refer to Section 204 04 4 Inspect the pads for wear or contamination install new if worn to or past specification 5 CAUTION Do not allow the rear disc brake caliper 2552 to hang from the rear wheel brake hose 2A442 Remove the rear disc brake caliper bolts and position the caliper aside 6 Remove the brake pads SECTION 206 04 Rear Disc Brake 2003 Mustang Workshop Manual Speci...

Page 584: ...brake lathe if necessary to machine the brake disc Measure the brake disc resurface and or install new as necessary 9 Compress the rear disc brake piston and adjuster 2B588 into rear disc brake caliper using Rear Caliper Piston Adjuster Installation ...

Page 585: ...s and polyglycols Avoid contact with eyes Wash hands thoroughly after handling If brake fluid contacts eyes flush eyes with running water for 15 minutes Get medical attention if irritation persists If taken internally drink water and induce vomiting Get medical attention immediately CAUTION Brake fluid is harmful to painted or plastic surfaces If brake fluid is spilled onto a painted or plastic su...

Page 586: ...7 Recheck the master cylinder fluid level ...

Page 587: ... rear disc support bracket 2B511 For additional information refer to Support Bracket in this section 2 Remove the brake disc 2C026 Installation 1 Follow the removal procedure in reverse order SECTION 206 04 Rear Disc Brake 2003 Mustang Workshop Manual ...

Page 588: ...sembly For additional information refer to Section 204 04 3 CAUTION Do not allow the rear disc brake caliper 2552 to hang from the rear wheel brake hose 2A442 Remove the rear disc brake caliper bolts and position the caliper aside 4 Remove the brake pads 5 Remove the rear disc support bracket 2B511 bolts and bracket SECTION 206 04 Rear Disc Brake 2003 Mustang Workshop Manual ...

Page 589: ...Installation 1 NOTE New bolts must be used when reinstalling the rear disc support bracket Follow the removal procedure in reverse order ...

Page 590: ... Remove the brake disc 2C026 For additional information refer to Disc in this section 2 Remove the brake disc shield bolts Installation 1 Follow the removal procedure in reverse order SECTION 206 04 Rear Disc Brake 2003 Mustang Workshop Manual ...

Page 591: ......

Page 592: ... 2 Drain the brake fluid from the rear disc brake caliper 3 Secure the rear disc brake caliper in a vise 4 Turn the rear disc brake piston and adjuster 2B588 counterclockwise with Rear Caliper Piston Adjuster SECTION 206 04 Rear Disc Brake 2003 Mustang Workshop Manual Special Tool s Rear Caliper Piston Adjuster 206 026 T87P 2588 A Rear Caliper Spring Compressor Set 206 S027 T87P 2588 B ...

Page 593: ...ng cover are spring loaded Use care when removing the parking brake lever pin retainer clip Remove the parking brake lever pin retainer clip Unload the spring tension from the parking brake lever pin retainer clip and spring cover using Screw and Cross Block a 6 mm washer head nut and a 1 2 inch drive 14 mm socket Remove the parking brake lever pin retainer clip with suitable snap ring pliers Remo...

Page 594: ...rom the push rod 10 Remove the parking brake lever 2A637 1 Remove the parking brake return spring 2456 2 Remove the limiting bolt 2A795 3 Remove the parking brake lever 4 Remove the parking brake lever shaft seal from the caliper bore Assembly 1 CAUTION Do not reuse piston seals or dust boots Install new seals or dust boots or damage to the vehicle can occur ...

Page 595: ...OTE Lightly lubricate the parking brake lever bore limiting bolt parking brake lever shaft and parking brake shaft recess with Silicone Dielectric Compound D7AZ 19A331 A or equivalent meeting Ford specification ESE M1C171 A Follow the disassembly procedure in reverse order ...

Page 596: ...PECIFICATIONS SECTION 206 05 Parking Brake and Actuation 2003 Mustang Workshop Manual Torque Specifications Description Nm Lb Ft Parking brake control to cowl nut 17 13 Brake hose clip mounting bolt 12 9 ...

Page 597: ... spring in the parking brake control continuously adjusts the cable tension in the system Brake Warning System A parking brake warning indicator is located in the instrument panel illuminates to signal the driver the parking brake is applied or to signal a low fluid condition remains lit when a brake malfunction has occurred SECTION 206 05 Parking Brake and Actuation 2003 Mustang Workshop Manual I...

Page 598: ......

Page 599: ...rt Symptom Chart Pinpoint Tests PINPOINT TEST A PARKING BRAKE WILL NOT APPLY SECTION 206 05 Parking Brake and Actuation 2003 Mustang Workshop Manual Visual Inspection Chart Mechanical Electrical Damaged parking brake control Binding damaged parking brake cables Parking brake signal switch Symptom Chart Condition Possible Sources Action Parking Brake Will Not Apply Parking brake control Parking bra...

Page 600: ...2 Release parking brake by pulling upward on hand lever and pushing release button Did parking brake release Yes GO to B2 No INSTALL a new parking brake control RESTORE the vehicle and TEST the system for normal operation B2 CHECK PARKING BRAKE CABLES Loosen tensioner Refer to Parking Brake Cable Tension Release in this section Move the gearshift lever to NEUTRAL position Rotate rear wheels by han...

Page 601: ......

Page 602: ...sistant inside the vehicle raise and support the vehicle For additional information refer to Section 100 02 4 Pull the parking brake cable and equalizer rearward 5 CAUTION Do not remove the steel pin until the parking brake cable and equalizer rear cable and conduits are connected to the parking brake control Pin removal releases the tension in the ratchet wheel causing the spring to unwind and re...

Page 603: ......

Page 604: ... console For additional information refer to Section 501 12 3 Remove the parking brake control studs 4 NOTE Self adjust pawl must be off to allow wind up Place the control handle in the fully downward position then pull the control handle forward to wind up the self adjusting mechanism 5 Insert a steel pin through hole in the lever to the ratchet wheel then carefully release the spring tension ont...

Page 605: ...ension on the cable so cable end does not fall out of equalizer Disconnect the parking brake cable Installation 1 NOTE Make sure cable ends are attached to the equalizer Follow the removal procedure in reverse order ...

Page 606: ......

Page 607: ...s removed the cable tension must be released Release the cable tension For additional information refer to Parking Brake Cable Tension Release in this section 2 Disconnect the parking brake rear cables and conduits 3 Remove the parking brake control nuts 4 Disconnect the parking brake cable SECTION 206 05 Parking Brake and Actuation 2003 Mustang Workshop Manual ...

Page 608: ...5 Pull the front cable and equalizer through the floorpan from inside the vehicle Installation 1 Follow the removal procedure in reverse order ...

Page 609: ......

Page 610: ...oved the cable tension must be released Release the cable tension For additional information refer to Parking Brake Cable Tension Release in this section 2 Disconnect the parking brake rear cable and conduit 3 Using a 13 mm 0 52 in box end wrench depress the conduit retaining prongs and remove the parking brake rear cable and conduit SECTION 206 05 Parking Brake and Actuation 2003 Mustang Workshop...

Page 611: ...he parking brake rear cable and conduit from the routing clip bolts 5 Disconnect the parking brake rear cable and conduit from the parking brake lever 2A637 6 Remove the clip from the rear disc brake caliper 2552 ...

Page 612: ...7 Remove the parking brake rear cable and conduit from the rear disc brake caliper Installation 1 Follow the removal procedure in reverse order ...

Page 613: ......

Page 614: ...ang Workshop Manual Torque Specifications Description Nm lb ft Brake master cylinder nuts 25 19 Brake pedal bracket nuts 25 19 Brake pedal bracket bolt 23 17 Brake fluid control valve 19 15 Hydraulic tube connections 17 13 Brake fluid control valve bracket nut 14 11 ...

Page 615: ... to prevent recontamination This vehicle is equipped with a brake pedal actuated dual brake system The system consists of the following power brake booster 2005 brake master cylinder 2140 brake pressure control valve 2B091 disc brake calipers 2B120 rear disc brake calipers 2553 brake tubes and hoses anti lock brake system ABS components SECTION 206 06 Hydraulic Brake Actuation 2003 Mustang Worksho...

Page 616: ...n stored in an open container Do not mix different types of brake fluid Brake Master Cylinder The brake master cylinder is a dual piston type The brake master cylinder operates as follows When the brake pedal 2455 is depressed pressure is applied by mechanical linkage to the primary and secondary piston Brake master cylinder pistons apply hydraulic pressure to the two hydraulic circuits Brake mast...

Page 617: ...pper tubing It is subject to fatigue cracking and corrosion which could result in brake tube failure Steel tubing is used throughout the brake hydraulic system All brake tube fittings must be correctly double flared to provide strong leakproof connections When bending the tubing to fit the underbody or rear axle contours be careful not to kink or crack the tube If a section of brake tube is damage...

Page 618: ...tion refer to Section 414 01 2 Remove the stoplight switch retaining pin 3 Slide the stoplight switch 13480 and booster push rod from the brake pedal pin 4 Remove the brake pedal bracket retaining bolt 5 Remove the brake pedal bracket retaining nuts SECTION 206 06 Hydraulic Brake Actuation 2003 Mustang Workshop Manual ...

Page 619: ...6 Remove the brake pedal and bracket Installation 1 To install reverse the removal procedure ...

Page 620: ......

Page 621: ...onnect the brake tubes 3 Remove the brake master cylinder nuts 4 Remove the brake master cylinder 2140 Installation 1 To install reverse the removal procedure Bleed the brake system For additional information refer to Section 206 00 SECTION 206 06 Hydraulic Brake Actuation 2003 Mustang Workshop Manual ...

Page 622: ......

Page 623: ...ydro Boost Removal 1 Disconnect the fluid level sensor connector 2 Disconnect the brake tubes 3 Remove the brake master cylinder nuts 4 Remove the brake master cylinder 2140 SECTION 206 06 Hydraulic Brake Actuation 2003 Mustang Workshop Manual ...

Page 624: ...Installation 1 To install reverse the removal procedure Bleed the brake system For additional information refer to Section 206 00 ...

Page 625: ......

Page 626: ...on 1 NOTE Whenever installing a new brake master cylinder reservoir install new grommets Install the brake master cylinder reservoir 1 Lubricate the two grommets with High Performance DOT 3 Brake Fluid C6AZ 19542 AB or equivalent fluid meeting Ford specification ESA M6C25 A and insert the grommets into the brake master cylinder 2140 2 Press the brake master cylinder reservoir into the grommets unt...

Page 627: ......

Page 628: ...Control Valve Removal 1 Disconnect the brake tubes 2 Remove the brake fluid control valve bracket nut Installation 1 To install reverse the removal procedure SECTION 206 06 Hydraulic Brake Actuation 2003 Mustang Workshop Manual ...

Page 629: ......

Page 630: ...07 Power Brake Actuation 2003 Mustang Workshop Manual Torque Specifications Description Nm lb ft Power brake booster nuts 25 19 Brake master cylinder nuts 25 19 Hydraulic tube connections 17 13 Power steering pressure lines 19 14 ...

Page 631: ...er cylinder 2140 is divided into separate chambers by the diaphragms will not operate if vacuum is restricted or if any of the vacuum related power brake components fail is installed as an assembly If the power assist fails the brake system will continue to operate with increased brake pedal effort Hose and Check Valve The power brake booster check valve 2365 SECTION 206 07 Power Brake Actuation 2...

Page 632: ...ned between the power brake booster and the power brake booster hose closes when the engine is turned off in the closed position traps engine vacuum in the power brake booster retains vacuum to provide several power assisted brake applications with the engine off Item Part Number Description 1 2140 Master cylinder 2 2005 Power brake booster ...

Page 633: ...pressure to provide at least two power assisted brake applications in the event the power steering pump fluid flow is interrupted For low assist concerns on vehicles equipped with the Hydro Boost system refer to Section 211 00 to check the power steering pump pressure and flow The brakes can also be applied manually if the reserve system is depleted Any leakage goes directly back to the power stee...

Page 634: ......

Page 635: ...the engine from starting 3 Crank the engine for several seconds 4 Check the fluid level in the power steering oil reservoir and add if necessary Install the powertrain control module PCM fuse 5 Start the engine 6 With the engine running turn the steering wheel 3600 from stop to stop twice Turn the engine off 7 Depress the brake pedal 2455 several times to discharge the accumulator 8 Repeat Steps 5...

Page 636: ......

Page 637: ...g For additional information refer to Section 303 12 3 Remove the brake master cylinder nuts 4 Position the brake master cylinder 2140 aside 5 With the engine off depress the brake pedal 2455 several times to discharge the accumulator Disconnect the booster vacuum hose 6 Remove the stoplight switch self locking pin SECTION 206 07 Power Brake Actuation 2003 Mustang Workshop Manual ...

Page 638: ...stoplight switch 13480 and the brake booster push rod from the brake pedal pin 8 Remove the power brake booster nuts 9 Remove the power brake booster 2005 Installation 1 Follow the removal procedure in reverse order ...

Page 639: ......

Page 640: ...be exposed to excessive heat Before discarding the accumulator drill a 1 6 mm 1 16 inch diameter hole in the end of the accumulator can to relieve the gas pressure Always wear safety glasses when performing this operation 1 With the engine off depress the brake pedal 2455 several times to discharge the accumulator 2 Disconnect the battery ground cable 14301 For additional information refer to Sect...

Page 641: ...t the power steering return line hose 3A005 6 Disconnect the power steering pressure lines 7 Remove the self locking pin 8 Remove the stoplight switch 13480 and the brake booster push rod from the brake pedal pin ...

Page 642: ...e power brake booster nuts 10 Remove the power brake booster nut 11 Remove the booster Installation 1 Follow the removal procedure in reverse order Install new Teflon seals on the power steering pressure fittings ...

Page 643: ...Bleed Hydro Boost For additional information refer to Hydro Boost Bleeding in this section Bleed the brake system For additional information refer to Section 206 00 ...

Page 644: ......

Page 645: ...nual Torque Specifications Description Nm lb ft lb in Anti lock brake control module screws 3 26 Brake line fittings to hydraulic control unit 19 14 Front anti lock brake sensor bolt 7 62 Hydraulic control unit to mounting bracket nuts 18 13 Rear anti lock brake sensor bolt 7 62 ...

Page 646: ...k brake control module 2C346 front anti lock brake sensor 2C205 front anti lock brake sensor indicator 2C182 hydraulic control unit 2C286 rear anti lock brake sensor 2C216 rear anti lock brake sensor indicator 2C189 yellow anti lock brake system ABS warning indicator SECTION 206 09A Anti Lock Control Rear 2003 Mustang Workshop Manual ...

Page 647: ...e the affected wheel returns to normal speed the anti lock brake control module returns the solenoid valves to their normal position and normal base braking resumes The anti lock brake control module is self monitoring When the ignition switch is turned to the RUN position the anti lock brake control module will do a preliminary electrical check and at approximately 12 km h 8 mph the pump motor is...

Page 648: ...rouble Code DTC Reference Chart to continue diagnostics 7 If no DTCs related to the concern are retrieved GO to Symptom Chart to continue diagnostics Anti Lock Brake Control Module Diagnostic Trouble Code DTC Index NOTE If a wheel speed signal fault or a pump motor fault is detected the yellow ABS warning indicator cannot be reset with the key OFF and key ON method The vehicle must be driven over ...

Page 649: ...sor Input Signal Missing ABS Go To Pinpoint Test H C1236 LR Anti Lock Brake Sensor Input Signal Missing ABS Go To Pinpoint Test H C1266 ABS Valve Power Relay Circuit Failure ABS Go To Pinpoint Test I Anti Lock Brake Control Module Parameter Identification PID Index PID Description Expected Value CCNTABS Number of Continuous DTCS in the Anti Lock Brake Control Module one count per bit BOO_ABS Brake...

Page 650: ...and Index Active Command Display Action ABS OUTPUT CONTROL ABS POWER OFF ON DSBL TOG OFF ON LF INLET OFF ON LF OUTLET OFF ON RF INLET OFF ON RF OUTLET OFF ON R INLET OFF ON R OUTLET OFF ON Symptom Chart NOTE Refer to the Wiring Diagrams for connector numbers stated in the Pinpoint tests Condition Possible Sources Action No communication with the anti lock brake control module CJB Fuse 29 15A Circu...

Page 651: ...Key in ON position Measure the voltage between anti lock brake control module C135 Pin 8 Circuit 601 LB PK harness side and ground Is the voltage greater than 10 volts Yes GO to A2 No REPAIR the circuit REPEAT the self test A2 CHECK THE ANTI LOCK BRAKE CONTROL MODULE GROUNDS Measure the resistance between anti lock brake control module C135 Pin 12 Circuit 1205 BK harness side and ground and betwee...

Page 652: ...e the battery voltage between the positive and negative battery posts with the key ON engine OFF KOEO and with the engine running Is the battery voltage between 10 and 13 volts with KOEO and between 11 and 17 volts with the engine running Yes GO to C2 No REFER to Section 414 00 C2 CHECK THE VOLTAGE TO THE ANTI LOCK BRAKE CONTROL MODULE Key in OFF position Disconnect Anti Lock Brake Control Module ...

Page 653: ...PLAMPS FOR CORRECT OPERATION Depress the brake pedal while checking the stoplamps Do the stop lamps illuminate Yes GO to D2 No REFER to Section 417 01 D2 CHECK THE BRAKE PEDAL INPUT TO THE ANTI LOCK BRAKE CONTROL MODULE Key in OFF position Disconnect Anti Lock Brake Control Module C135 Measure the voltage between anti lock brake control module C135 Pin 6 Circuit 511 LG harness side and ground whil...

Page 654: ...EPEAT the self test E3 CHECK CIRCUIT 1205 BK FOR AN OPEN Measure the resistance between anti lock brake control module C135 Pin 12 Circuit 1205 BK harness side and ground Is the resistance less than 5 ohms Yes GO to E4 No REPAIR the circuit CLEAR the DTCs REPEAT the self test E4 CHECK THE PUMP MOTOR FOR OPERATION Disconnect Pump Motor Connector Connect a 30A fused heavy jumper wire between the pos...

Page 655: ...Key in ON position Measure the voltage between anti lock brake control module C135 Pins harness side and ground as follows Is any voltage present DTC Anti Lock Brake Control Module C135 Pin Circuit C1145 RF 4 514 YE RD C1155 LF 20 521 TN OG C1165 RR 1 494 TN LG C1175 LR 22 496 OG Yes REPAIR the circuit in question CLEAR the DTCs REPEAT the self test No GO to F2 F2 CHECK THE SUSPECT ANTI LOCK BRAKE...

Page 656: ...ary CLEAR the DTCs REPEAT the self test If LF REPAIR Circuit 521 TN OG and Circuit 522 TN BK as necessary CLEAR the DTCs REPEAT the self test If RR REPAIR Circuit 494 TN LG and Circuit 492 BN as necessary CLEAR the DTCs REPEAT the self test If LR REPAIR Circuit 496 OG and Circuit 499 GY BK as necessary CLEAR the DTCs REPEAT the self test No INSTALL a new anti lock brake sensor REFER to Sensor Fron...

Page 657: ...1165 RR C135 Pin 3 C3117 Pin 1 492 BN C1175 LR C135 Pin 22 C3116 Pin 2 496 OG C1175 LR C135 Pin 23 C3116 Pin 1 499 GY BK test F5 CHECK THE ANTI LOCK BRAKE SENSOR Measure the resistance between suspect anti lock brake sensor Pin 1 component side and suspect anti lock brake sensor Pin 2 component side Is the resistance between 1280 and 1920 front or 1830 and 2760 rear ohms Yes INSTALL a new anti loc...

Page 658: ...e DTC index If no DTCs are retrieved the system is OK Test Step Result Action to Take H1 CHECK THE SUSPECT ANTI LOCK BRAKE SENSOR Check the suspect anti lock brake sensor mounting Check the suspect anti lock brake sensor for excessive dirt build up obstructions and damage Is the suspect anti lock brake sensor and mounting OK Yes GO to H2 No REPAIR as necessary CLEAR the DTCs REPEAT the self test H...

Page 659: ...trol Module C135 Measure the voltage between anti lock brake control module C135 Pin 13 Circuit 534 YE LG harness side and ground Is the voltage greater than 10 volts Yes GO to I2 No REPAIR the circuit CLEAR the DTCs REPEAT the self test I2 CHECK CIRCUIT 532 OG YE FOR AN OPEN Key in OFF position Key in ON position Measure the voltage between anti lock brake control module C135 Pin 14 Circuit 532 O...

Page 660: ...or in the instrument cluster Does the yellow ABS indicator illuminate with the shorting bar released and turn OFF with the shorting bar depressed Yes INSTALL a new anti lock brake control module REFER to Module TEST the system for normal operation No REFER to Section 413 01 Test Step Result Action to Take K1 CHECK THE VEHICLE COMPONENTS Check the brake pedal and power booster brake master cylinder...

Page 661: ... NOTE The scan tool will energize the valves for only two seconds per trigger press Have an assistant rotate the LF wheel immediately after depressing trigger Does the LF wheel rotate Yes GO to L4 No GO to L8 L4 CHECK THE RF ABS VALVE OPERATION NOTE Trigger must be depressed twice Each press will run the pump motor for two seconds Trigger the anti lock brake control module active command PMP MOTOR...

Page 662: ...t Trigger the anti lock brake control module active command R INLET and R OUTLET NOTE The scan tool will energize the valves for only two seconds per trigger press Have an assistant rotate the LR and RR wheels immediately after depressing trigger Does the LR or RR wheel rotate Yes The ABS system is operating correctly No GO to L8 L8 CHECK FOR DTCS Carry out the anti lock brake control module self ...

Page 663: ...Section 205 02B 2 Using the special tool remove the anti lock brake sensor indicator from the axle shaft SECTION 206 09A Anti Lock Control Rear 2003 Mustang Workshop Manual Special Tool s Pinion Bearing Cone Remover 205 D002 D79P 4621A Axle Bearing Seal Plate 205 090 T75L 1165 B Sensing Ring Replacer 206 041 T89P 20202 A ...

Page 664: ...lation 1 Using the special tools align the rear anti lock brake sensor indicator to the rear axle shaft 2 Using the special tools press the rear anti lock brake sensor on the rear axle shaft to specification ...

Page 665: ...3 Install the rear axle shaft bearing refer to Section 205 02A ...

Page 666: ...heel anti lock brake system 4WABS with traction control is shown the 4WABS without traction control system is similar with one less hydraulic line NOTE Plug brake lines to prevent any brake fluid loss Disconnect the brake lines from the hydraulic control unit HCU 4 Remove the HCU bracket nuts to HCU 5 Remove the HCU SECTION 206 09A Anti Lock Control Rear 2003 Mustang Workshop Manual ...

Page 667: ...e the anti lock brake control module screws 8 Remove the anti lock brake control module from the HCU Installation 1 NOTE The brake system must be bled after the HCU is installed or replaced Refer to Section 206 00 To install reverse the removal procedure ...

Page 668: ......

Page 669: ...ical connector 3 Remove the anti lock brake control module screws 4 Remove the anti lock brake control module from the HCU Installation 1 NOTE The brake system must be bled after the HCU is installed or replaced Refer to Section 206 00 To install reverse the removal procedure SECTION 206 09A Anti Lock Control Rear 2003 Mustang Workshop Manual ...

Page 670: ......

Page 671: ...rew 3 Remove the inner fender splash shield 3 Remove the front anti lock brake sensor electrical connector 4 Remove the front anti lock brake sensor harness from the anti lock brake sensor harness clips 5 Remove the front anti lock brake sensor 1 Remove the front anti lock brake sensor bolt 2 Remove the anti lock brake sensor harness from the harness clips 3 Remove the front anti lock brake sensor...

Page 672: ...Installation 1 To install reverse the removal procedure ...

Page 673: ......

Page 674: ...o Section 100 02 4 Remove the rear anti lock brake sensor harness from the floor pan 5 Remove the anti lock brake sensor harness bracket bolt 6 NOTE The sensor may be siezed to the axle Use Rust Penetrant and Inhibitor F2AZ 19A501 A meeting Ford specification ESR M99C56 A to loosen the sensor for removal Remove the rear anti lock brake sensor SECTION 206 09A Anti Lock Control Rear 2003 Mustang Wor...

Page 675: ...ar anti lock brake sensor Installation 1 NOTE Be sure to apply High Temperature Nickel Anti Sieze Lubricant F6AZ 9L494 AA meeting Ford specification ESE M124A A to the sensor body where it will make contact when installed To install reverse the removal procedure ...

Page 676: ...hop Manual Torque Specifications Description Nm lb ft lb in Anti lock brake control module screws 3 26 Brake line fittings to hydraulic control unit 19 14 Front anti lock brake sensor bolt 7 62 Hydraulic control unit to mounting bracket nuts 18 13 Rear anti lock brake sensor bolt 7 62 ...

Page 677: ...e 2C346 front anti lock brake sensor 2C204 2C205 front anti lock brake sensor indicator 2C182 hydraulic control unit 2C286 powertrain control module 12A650 rear anti lock brake sensor 2C190 2C216 rear anti lock brake sensor indicator 2C189 traction control switch yellow anti lock brake system ABS warning indicator SECTION 206 09B Anti Lock Control Traction Control 2003 Mustang Workshop Manual ...

Page 678: ...ock brake control module will do a preliminary electrical check and at approximately 12 km h 8 mph the pump motor is turned on for approximately one half second Also during all phases of operation the anti lock brake control module after the vehicle is in motion checks for correct operation of the anti lock brake sensors Any malfunction of the ABS will cause the ABS to shut off and ABS warning ind...

Page 679: ...us diagnostic trouble codes DTCs erase the continuous DTCs and carry out self test diagnostics for the anti lock brake control module 6 If the DTCs retrieved are related to the concern go to the Anti Lock Brake Control Module Diagnostic Trouble Code DTC Index to continue diagnostics 7 If no DTCs related to the concern are retrieved GO to Symptom Chart to continue diagnostics Anti Lock Brake Contro...

Page 680: ...Test H C1234 RF Anti Lock Brake Sensor Input Signal Missing ABS TC Go To Pinpoint Test H C1235 RR Anti Lock Brake Sensor Input Signal Missing ABS TC Go To Pinpoint Test H C1236 LR Anti Lock Brake Sensor Input Signal Missing ABS TC Go To Pinpoint Test H C1266 ABS Valve Power Relay Circuit Failure ABS TC INSTALL a new anti lock brake control module REFER to Module REPEAT the self test C1805 Mismatch...

Page 681: ...et Valve OFF OFFO OFF B OFF G OFFO G OFF BG OFFOBG ON ONO ON B ON G ONO G ON BG ONOBG ABSRF_I RF ABS Inlet Valve OFF OFFO OFF B OFF G OFFO G OFF BG OFFOBG ON ONO ON B ON G ONO G ON BG ONOBG ABSRF_O RF ABS Outlet Valve OFF OFFO OFF B OFF G OFFO G OFF BG OFFOBG ON ONO ON B ON G ONO G ON BG ONOBG ABSLR_I LR ABS Inlet Valve OFF OFFO OFF B OFF G OFFO G OFF BG OFFOBG ON ONO ON B ON G ONO G ON BG ONOBG A...

Page 682: ...F B OFF G OFFO G OFF BG OFFOBG ON ONO ON B ON G ONO G ON BG ONOBG Anti Lock Brake Control Module Active Command Index Active Command Display Action ABS OUTPUT CONTROL ABS POWER OFF ON DSBL TOG OFF ON LF INLET OFF ON LF OUTLET OFF ON RF INLET OFF ON RF OUTLET OFF ON LR INLET OFF ON LR OUTLET OFF ON RR INLET OFF ON RR OUTLET OFF ON TRACTION CONTROL PRIMARY AND SWITCHING VALVE CONTROL LF TC PRV OFF O...

Page 683: ...REFER to Section 206 00 Poor vehicle tracking during anti lock function Air in the brake system Hydraulic control unit HCU Base brake system Go To Pinpoint Test K REFER to Section 206 00 The traction control is inoperative does not operate correctly CJB 5 15A Circuitry Traction control switch Instrument cluster Anti lock brake control module Go To Pinpoint Test L The traction control indicator is ...

Page 684: ...ke control module REFER to Module REPEAT the self test No REPAIR the circuit in question REPEAT the self test Test Step Result Action to Take B1 CHECK THE COMMUNICATIONS TO THE ANTI LOCK BRAKE CONTROL MODULE Check the communications to the anti lock brake control module Does the scan tool communicate with the anti lock brake control module Yes INSTALL a new anti lock brake control module REFER to ...

Page 685: ...he voltage greater than 10 volts Yes GO to C3 No REPAIR the circuit CLEAR the DTCs REPEAT the self test C3 CHECK THE ANTI LOCK BRAKE CONTROL MODULE GROUNDS Measure the resistance between anti lock brake control module C141 Pin 12 Circuit 1205 BK harness side and ground and between anti lock brake control module C141 Pin 15 Circuit 397 BK WH harness side and ground Are the resistances less than 5 o...

Page 686: ... the brake pedal released Yes INSTALL a new anti lock brake control module REFER to Module REPEAT the self test No REPAIR Circuit 511 LG and Circuit 810 RD LG as necessary CLEAR the DTCs REPEAT the self test Test Step Result Action to Take E1 CHECK THE PUMP MOTOR FOR CONTINUOUS OPERATION Check the pump motor for continuous operation Is the pump motor running continuously Yes INSTALL a new anti loc...

Page 687: ...A fused heavy jumper wire between the positive battery post and pump motor connector Pin 1 component side and momentarily connect a heavy jumper between negative battery post and pump motor connector Pin 2 component side Does the pump motor operate Yes INSTALL a new anti lock brake control module REFER to Module REPEAT the self test No INSTALL a new HCU REFER to Hydraulic Control Unit CLEAR the DT...

Page 688: ... OG C1165 RR 1 494 TN LG C1175 LR 22 496 OG test No GO to F2 F2 CHECK THE SUSPECT ANTI LOCK BRAKE SENSOR CIRCUIT FOR SHORT TO GROUND Key in OFF position Measure the resistance between anti lock brake control module C141 Pins harness side and ground as follows DTC Anti Lock Brake Control Module C141 Pin Circuit C1145 RF 4 514 YE RD C1155 LF 20 521 TN OG C1165 RR 1 494 TN LG C1175 LR 22 496 OG Yes G...

Page 689: ...t 496 OG and Circuit 499 GY BK as necessary CLEAR the DTCs REPEAT the self test No INSTALL a new anti lock brake sensor REFER to Sensor Front or Sensor Rear CLEAR the DTCs REPEAT the self test F4 CHECK THE SUSPECT ANTI LOCK BRAKE SENSOR CIRCUIT FOR FOR AN OPEN Key in OFF position Measure the resistance between anti lock brake control module C141 Pins harness side and suspect anti lock brake sensor...

Page 690: ... rear ohms Yes INSTALL a new anti lock brake control module REFER to Module REPEAT the self test No INSTALL a new anti lock brake sensor REFER to Sensor Front or Sensor Rear CLEAR the DTCs REPEAT the self test Test Step Result Action to Take G1 CHECK THE VEHICLE COMPONENTS Check for correct wheel and tire size front to rear and side to side Check for excessive bearing end play Check the anti lock ...

Page 691: ... H2 CHECK THE SUSPECT ANTI LOCK BRAKE SENSOR INDICATOR Check the suspect anti lock brake sensor indicator for corrosion nicks bridged teeth damaged teeth correct mounting and alignment with the anti lock brake sensor Check the air gap and bearing end play Is the suspect anti lock brake sensor indicator OK Yes GO to H3 No INSTALL a new anti lock brake sensor indicator REFER to Sensor Indicator Fron...

Page 692: ...d power booster brake master cylinder for correct attachment Are the components OK Yes GO to J2 No REPAIR as necessary TEST the system for normal operation J2 BLEED THE BRAKE SYSTEM Bleed the brake system REFER to Section 206 00 Check for spongy brake pedal Is the brake pedal spongy Yes INSTALL a new HCU REFER to Hydraulic Control Unit TEST the system for normal operation No The brake system is OK...

Page 693: ...e system for normal operation No GO to K5 K5 CHECK THE RF ABS VALVE RELEASE Apply moderate brake pedal effort Trigger the anti lock brake control module active command RF INLET and RF OUTLET NOTE The scan tool will energize the valves for only two seconds per trigger press Have an assistant rotate the RF wheel immediately after depressing trigger Does the RF wheel rotate Yes GO to K6 No GO to K10 ...

Page 694: ...an assistant rotate the RR wheel immediately after depressing trigger Does the RR wheel rotate Yes The ABS system is operating correctly No GO to K10 K10 CHECK FOR DTCS Carry out the anti lock brake control module self test Are any DTCs retrieved Yes GO to the Anti Lock Brake Control Module Diagnostic Trouble Code DTC Index No INSTALL a new HCU REFER to Hydraulic Control Unit TEST the system for n...

Page 695: ...tion Measure the voltage between traction control switch C239 Pin 3 Circuit 489 PK BK harness side and ground Is the voltage greater than 10 volts Yes INSTALL a new traction control switch TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation Test Step Result Action to Take M1 CHECK CIRCUIT 960 BK LB Key in OFF position Disconnect Instrument Cluster C251 D...

Page 696: ...IR the circuit TEST the system for normal operation M3 CHECK THE TRACTION CONTROL SWITCH INDICATOR Key in OFF position Connect Traction Control Switch C239 Key in ON position Momentarily connect a fused 10A jumper wire between instrument cluster C251 Pin 8 Circuit 960 BK LB harness side and ground while observing the traction control switch indicator Does the traction control switch indicator illu...

Page 697: ......

Page 698: ...n 205 02B 2 Using the special tool remove the anti lock brake sensor indicator from the axle shaft SECTION 206 09B Anti Lock Control Traction Control 2003 Mustang Workshop Manual Special Tool s Pinion Bearing Cone Remover 205 D002 D79P 4621A Axle Bearing Seal Plate 205 090 T75L 1165 B Sensing Ring Replacer 206 041 T89P 20202 A ...

Page 699: ...lation 1 Using the special tools align the rear anti lock brake sensor indicator to the rear axle shaft 2 Using the special tools press the rear anti lock brake sensor on the rear axle shaft to specification ...

Page 700: ...3 Install the rear axle shaft bearing refer to Section 205 02A ...

Page 701: ...nti lock brake system 4WABS with traction control is shown the 4WABS without traction control system is similar with one less hydraulic line NOTE Plug brake lines to prevent any brake fluid loss Disconnect the brake lines from the hydraulic control unit HCU 4 Remove the HCU bracket nuts to HCU 5 Remove the HCU SECTION 206 09B Anti Lock Control Traction Control 2003 Mustang Workshop Manual ...

Page 702: ...e the anti lock brake control module screws 8 Remove the anti lock brake control module from the HCU Installation 1 NOTE The brake system must be bled after the HCU is installed or replaced Refer to Section 206 00 To install reverse the removal procedure ...

Page 703: ......

Page 704: ...onnector 3 Remove the anti lock brake control module screws 4 Remove the anti lock brake control module from the HCU Installation 1 NOTE The brake system must be bled after the HCU is installed or replaced Refer to Section 206 00 To install reverse the removal procedure SECTION 206 09B Anti Lock Control Traction Control 2003 Mustang Workshop Manual ...

Page 705: ......

Page 706: ...Remove the inner fender splash shield 3 Remove the front anti lock brake sensor electrical connector 4 Remove the front anti lock brake sensor harness from the anti lock brake sensor harness clips 5 Remove the front anti lock brake sensor 1 Remove the front anti lock brake sensor bolt 2 Remove the anti lock brake sensor harness from the harness clips 3 Remove the front anti lock brake sensor SECTI...

Page 707: ...Installation 1 To install reverse the removal procedure ...

Page 708: ......

Page 709: ...ion 100 02 4 Remove the rear anti lock brake sensor harness from the floor pan 5 Remove the anti lock brake sensor harness bracket bolt 6 NOTE The sensor may be siezed to the axle Use Rust Penetrant and Inhibitor F2AZ 19A501 A meeting Ford specification ESR M99C56 A to loosen the sensor for removal Remove the rear anti lock brake sensor SECTION 206 09B Anti Lock Control Traction Control 2003 Musta...

Page 710: ...ar anti lock brake sensor Installation 1 NOTE Be sure to apply High Temperature Nickel Anti Sieze Lubricant F6AZ 9L494 AA meeting Ford specification ESE M124A A to the sensor body where it will make contact when installed To install reverse the removal procedure ...

Page 711: ... floor console finish panel Lifting from both sides detach the floor console finish panel 2 Disconnect the electrical connector and position the finish panel out of the way 3 Reaching behind the center finish panel push and detach the switch from the finish panel 4 Disconnect the electrical connector and remove the switch SECTION 206 09B Anti Lock Control Traction Control 2003 Mustang Workshop Man...

Page 712: ...5 To install reverse the removal procedure ...

Page 713: ...8 liters minute 2 6 gpm Fluid 74 80 C 165 175 F Engine at 1 500 rpm Pressure 1 034 kPa 150 psi Fluid 74 80 C 165 175 F Engine at 1 500 rpm Minimum capacity 3 4 liters minute 0 9 gpm Fluid 74 80 C 165 175 F Engine at idle Pressure at 5 102 kPa 750 psi Relief pressure 7 240 8 400 kPa 1 050 1 230 psi Power Steering Pump CIII Flow 9 8 liters minute 2 6 gpm Fluid 74 80 C 165 175 F Engine at 1 500 rpm P...

Page 714: ...Relief pressure 8 274 9 510 kPa 1 200 1 380 psi ...

Page 715: ...r Steering Pump Steering System Components 4 6L Engine CIII Power Steering Pump SECTION 211 00 Steering System General Information 2003 Mustang Workshop Manual Item Part Number Description 1 3A714 Power steering hose 2 3A674 Power steering pump 3 3493 Power steering hose 4 3504 Steering gear 5 3A130 Tie rod end 6 3493 Power steering hose 7 3D746 Power steering fluid cooler ...

Page 716: ...nformation on the power steering fluid cooler refer to Section 211 02 For information on the power steering pump refer to Section 211 02 For information on the steering gear refer to Section 211 02 Item Part Number Description 1 3A713 Power steering hose 2 3R700 Power steering pump reservoir 3 3A714 Power steering hose 4 2B559 Hydro boost assy 5 3E525 Power steering hose 6 3504 Steering gear 7 3A1...

Page 717: ......

Page 718: ...nary checks before repairing the steering system SECTION 211 00 Steering System General Information 2003 Mustang Workshop Manual Special Tool s Dial Thermometer 0 220 F 023 R0007 or Equivalent Hand Held Automotive Meter 105 R0053 or Equivalent Power Steering Analyzer 211 F001 014 00207 or Equivalent Spring Scale 211 034 T74P 3504 Y Tach Adapter 418 F102 007 00061 or Equivalent Tie Rod End Remover ...

Page 719: ...ring fluid level is within the appropriate indicated range hot for the 3 8L engine and cold for the 4 6L engine Add Motorcraft MERCON Multi Purpose ATF XT 2 QDX or MERCON equivalent 5 Air Bleeding Verify that there is no air in the power steering system Run the engine 6007 until it reaches normal operating temperature Turn the steering wheel to the left and right several times without hitting the ...

Page 720: ...ar 3504 With the engine running turn the steering wheel from stop to stop several times Do not hold steering wheel at stops Check for leaks Repair as necessary if leaks are observed 7 Turning Effort Check Refer to Turning Effort Test under Component Tests in this section 8 Visually inspect for obvious signs of mechanical damage refer to the following chart ...

Page 721: ... free play is considered normal Feedback Feedback is a roughness felt in the steering wheel when the vehicle is driven over rough pavement Hard Steering or Lack of Assist Hard steering or lack of assist is experienced when the steering wheel effort exceeds specifications Hard steering can remain constant through the full turn or occur near the end of a turn It is important to know the difference b...

Page 722: ... lower steering column shaft U joints INSTALL a new lower steering column shaft REFER to Section 211 04 Damaged fractured steering column bearing s REPAIR the steering column REFER to Section 211 04 Power steering pump GO to Pump Flow and Pressure Test Component Test in this section Suspension components REFER to Section 204 00 for suspension system diagnosis and testing Steering gear internal lea...

Page 723: ...t U joints INSTALL a new lower steering column shaft REFER to Section 211 04 Loose worn or damaged steering column bearing s INSTALL new steering column bearings REFER to Section 211 04 Suspension components REFER to Section 204 00 for suspension system diagnosis and testing Drift Pull Unevenly loaded or overloaded vehicle INFORM the customer of incorrect vehicle loading Wheel alignment CHECK the ...

Page 724: ...ing s INSTALL new steering column bearing s REFER to Section 211 04 Poor Returnability Sticky Steering Binding lower steering column shaft U joints INSTALL a new lower steering column shaft REFER to Section 211 04 Loose worn or damaged front wheel spindle tie rod GO to the Tie Rod Articulation Torque Component Test Loose worn or damaged tie rod ends GO to the Steering Linkage Component Test Suspen...

Page 725: ... the parking brake 2 Insert a thermometer into the power steering pump reservoir 3 CAUTION Do not hold the steering wheel against the stops for more than three to five seconds at a time Damage to the power steering pump will occur Idle the engine for two to three minutes Turn the steering wheel from stop to stop several times to warm the fluid to 50 60 C 122 140 F 4 With the engine running attach ...

Page 726: ...ord the flow rate If the flow is less than the specified flow rate then install a new power steering pump For additional information refer to Section 211 02 8 CAUTION Do not allow the gate valve to remain closed for more than 5 seconds Completely close and partially open the gate valve 3 times Record the pressure relief valve actuation pressure reading If the pressure does not meet the relief pres...

Page 727: ...e threaded portion of the front wheel spindle tie rod and measure the force required to move the front wheel spindle tie rod Refer to Tie Rod Articulation Torque in General Specifications in this section 4 If the force required to move the front wheel spindle tie rod does not meet the specifications install a new front wheel spindle tie rod For additional information refer to Section 211 02 Steeri...

Page 728: ......

Page 729: ...N Multi Purpose ATF XT 2 QDX or MERCON equivalent 6 CAUTION Do not crank the engine for more than 15 seconds at a time Allow the starter to cool for 1 minute before cranking again Premature starter failure can occur CAUTION Do not hold the steering wheel against the stops for more than three to five seconds at a time Damage to the power steering pump will occur Turn the steering wheel from stop to...

Page 730: ...ore than three to five seconds at a time Damage to the power steering pump will occur Start the engine and turn the steering wheel from stop to stop 12 CAUTION Do not overfill the reservoir NOTE If the power steering system is noisy and is accompanied by evidence of aerated fluid it will be necessary to purge the power steering system Check the fluid level If necessary fill the reservoir to the co...

Page 731: ...N Multi Purpose ATF XT 2 QDX or MERCON equivalent 6 CAUTION Do not crank the engine for more than 15 seconds at a time Allow the starter to cool for 1 minute before cranking again Premature starter failure can occur CAUTION Do not hold the steering wheel against the stops for more than three to five seconds at a time Damage to the power steering pump could occur Turn the steering wheel from stop t...

Page 732: ...ore than three to five seconds at a time Damage to the power steering pump will occur Start the engine and turn the steering wheel from stop to stop 12 CAUTION Do not overfill the reservoir NOTE If the power steering system is noisy and is accompanied by evidence of aerated fluid it will be necessary to purge the power steering system Check the fluid level If necessary fill the reservoir to the co...

Page 733: ...rformed prior to any component repair for which power steering noise complaints are accompanied by evidence of aerated fluid Remove the reservoir cap Check the fluid level If necessary fill the reservoir to the correct level Use Motorcraft MERCON Multi Purpose ATF XT 2 QDX or MERCON equivalent 2 Tightly insert the Vacuum Pump stopper into the reservoir 3 Start the vehicle 4 Using the special tool ...

Page 734: ...l 6 CAUTION Do not overfill the reservoir Check the fluid level If necessary fill the reservoir to the proper level Use Motorcraft MERCON Multi Purpose ATF XT 2 QDX or MERCON equivalent 7 Reinstall the special tool Apply and maintain maximum vacuum ...

Page 735: ...ng pump will occur Cycle the steering wheel fully to the left and right every 30 seconds for approximately five minutes 9 Stop the engine release the vacuum and remove the special tool 10 Install the reservoir cap 11 Check for fluid leaks at all of the connections If the power steering fluid shows signs of air repeat this procedure ...

Page 736: ...rformed prior to any component repair for which power steering noise complaints are accompanied by evidence of aerated fluid Remove the reservoir cap Check the fluid level If necessary fill the reservoir to the correct level Use Motorcraft MERCON Multi Purpose ATF XT 2 QDX or MERCON equivalent 2 Tightly insert the Vacuum Pump stopper into the reservoir 3 Start the vehicle 4 Using the special tool ...

Page 737: ...l 6 CAUTION Do not overfill the reservoir Check the fluid level If necessary fill the reservoir to the correct level Use Motorcraft MERCON Multi Purpose ATF XT 2 QDX or MERCON equivalent 7 Reinstall the special tool Apply and maintain maximum vacuum ...

Page 738: ...ng pump will occur Cycle the steering wheel fully to the left and right every 30 seconds for approximately five minutes 9 Stop the engine release the vacuum and remove the special tool 10 Install the reservoir cap 11 Check for fluid leaks at all of the connections If the power steering fluid shows signs of air repeat this procedure ...

Page 739: ...tion 100 02 4 CAUTION Do not crank the engine for more than 15 seconds at a time Allow the starter to cool for 1 minute before cranking again Premature starter failure can occur CAUTION Do not hold the steering wheel against the stops for more than three to five seconds at a time Damage to the power steering pump will occur Turn the steering wheel from stop to stop while cranking the engine 5 Lowe...

Page 740: ......

Page 741: ... M1C171 A Steering Gear Grease C3AZ 19578 A ESW M1C87 A Torque Specifications Description Nm lb ft lb in Front wheel spindle tie rod 100 74 Power steering pump mounting bolts CII pump 51 38 Power steering pump mounting bolts CIII pump 25 18 Pressure line fitting CII pump 40 30 Pressure line fitting CIII pump 65 48 Pressure line fitting 30 22 Return line fitting steering gear 30 22 Steering gear mo...

Page 742: ......

Page 743: ...ystem Components 4 6L Engine SECTION 211 02 Power Steering 2003 Mustang Workshop Manual Item Part Number Description 1 3A714 Power steering hose 2 3A674 Power steering pump 3 3493 Power steering hose 4 3504 Steering gear 5 3A130 Tie rod end 6 3493 Power steering hose 7 3D746 Power steering fluid cooler ...

Page 744: ...eturn hose 2 3R700 Power steering pump reservoir 3 3A714 Power steering hose 4 Hydroboost unit 5 3E525 Power steering reservoir pump hose 6 3504 Steering gear 7 3289 Tie rod end 8 3A713 Power steering return hose 9 3D746 Power steering fluid cooler 10 3A674 Power steering pump ...

Page 745: ...olt 2 req d 3 72044 S36 Cotter pin 2 req d 4 385002 S2 Nut 2 req d 5 3289 Tie rod end 2 req d 6 385032 S2 Nut 2 req d 7 3504 Steering gear 8 N803734 S2 Washer 2 req d 9 N620483 S60 Nut 2 req d 10 3F640 Steering gear mounting bracket housing insulator 2 req d Item Part Number Description 1 Oil flow left turn ...

Page 746: ...entification CAUTION Always use the ID code when ordering service parts The steering gear identification code is stamped into the housing 2 To left turn port 3 To right turn port 4 Return port out 5 Pressure port in 6 Oil flow right turn 7 Air transfer tube between bellows ...

Page 747: ...n a tag attached to the power steering pump Item Part Number Description 1 Steering gear housing 2 Mounting boss 3 Shift code 4 Day code 5 Month code 6 Build year 7 Steering gear model code Item Part Number Description 1 Model code 2 For manufacturing purposes only 3 Day of the month A Jan B Feb etc I is not used 4 Shift 5 Month 6 Year ...

Page 748: ......

Page 749: ... 2 Disconnect the power steering hoses Remove the reservoir Installation 1 To install reverse the removal procedure 2 Fill and leak check the power steering system For additional information refer to Section 211 00 SECTION 211 02 Power Steering 2003 Mustang Workshop Manual ...

Page 750: ......

Page 751: ...e seal ring 2 Disconnect the power steering hose 3 Remove the pulley For additional information refer to Pulley CII Pump in this section 4 Remove bolts and the power steering pump 3A674 SECTION 211 02 Power Steering 2003 Mustang Workshop Manual Special Tool s Teflon Seal Replacer Set 211D027 D90P 3517 A or equivalent ...

Page 752: ...5 To install reverse the removal procedure Using the special tool install a new seal ring 6 Fill and leak check the power steering system For additional information refer to Section 211 00 ...

Page 753: ......

Page 754: ... Pulley CIII Pump in this section 2 Remove the bolt and bracket 3 Disconnect the power steering hoses Remove and discard the seal ring 4 Remove bolts and the power steering pump 3A674 SECTION 211 02 Power Steering 2003 Mustang Workshop Manual Special Tool s Teflon Seal Replacer Set 211 D027 D90P 3517 A or equivalent ...

Page 755: ...5 To install reverse the removal procedure Using the special tool install a new seal ring 6 Fill and leak check the power steering system For additional information refer to Section 211 00 ...

Page 756: ......

Page 757: ...formation refer to Section 303 05 2 Using the special tool remove the pulley Installation 1 Using the special tool install the pulley SECTION 211 02 Power Steering 2003 Mustang Workshop Manual Special Tool s Pump Pulley Installer 211 009 T65P 3A733 C Pump Pulley Remover 211 016 T69L 10300 B ...

Page 758: ...2 Install the drive belt For additional information refer to Section 303 05 ...

Page 759: ...ey Inspect the pulley for paint marks in the web area near the hub If there are two paint marks discard and install a new pulley If there is no paint or one paint mark use a paint pencil to mark the web area of the pulley near the hub Installation 1 Using the special tool install a new pulley SECTION 211 02 Power Steering 2003 Mustang Workshop Manual Special Tool s Pump Pulley Replacer 211 185 T91...

Page 760: ...2 Install the drive belt For additional information refer to Section 303 05 3 Lower the vehicle ...

Page 761: ...iew illustration in Description and Operation for the hose routing and retention points 2 When connecting a fitting with a seal ring a new seal ring must be installed The special tool is used to install the return line connector seal and the pressure line connector seal 3 Fill purge and leak check the system For additional information refer to Section 211 00 SECTION 211 02 Power Steering 2003 Must...

Page 762: ......

Page 763: ...connect the power steering hoses 3 Remove the bolt and routing bracket 4 Remove the bolts and the power steering fluid cooler Installation 1 To install reverse the removal procedure 2 Fill and leak check the power steering system For additional information refer to Section 211 SECTION 211 02 Power Steering 2003 Mustang Workshop Manual ...

Page 764: ...00 ...

Page 765: ...nal information refer to Section 100 02 3 Remove the front wheels and tires For additional information refer to Section 204 04 4 Remove the cotter pin and nut Discard the cotter pin 5 Using the special tool disconnect the tie rod end SECTION 211 02 Power Steering 2003 Mustang Workshop Manual Special Tool s Teflon Seal Replacer Set 211 D027 D90P 3517 A or Equivalent Tie Rod End Remover 211 001 TOOL...

Page 766: ...ot rotate the steering wheel when the lower steering column shaft is disconnected or damage to the air bag sliding contact will result Disconnect the steering column intermediate shaft coupling 3A525 10 Remove the nuts washers and bolts Position the steering gear 3504 forward 11 Disconnect the power steering hoses Remove and discard the seal rings Plug or cap the power steering hoses and steering ...

Page 767: ...12 Remove the steering gear Installation 1 To install reverse the removal procedure Using the special tool install a new seal ring Install a new pinch bolt ...

Page 768: ...2 Fill and leak check the power steering system For additional information refer to Section 211 00 ...

Page 769: ...ly All steering gears 1 Remove the steering gear mounting bracket housing insulators Discard worn or damaged steering gear mounting bracket housing insulators SECTION 211 02 Power Steering 2003 Mustang Workshop Manual Special Tool s Head Mounting Fixture 303 D041 D83L 500 B1 or Equivalent Inner Tie Rod Socket Tool 211 D025 D90P 3290 A or Equivalent Steering Gear Holding Fixture 211 D011 D87P 3504 ...

Page 770: ...ering gear 6 Place an alignment mark on the tie rod ends nuts and front wheel spindle tie rods Remove the tie rod ends and nuts 7 CAUTION Use care not to damage the front suspension steering ball stud dust seals If the front suspension steering ball stud dust seals are damaged this will allow contamination into the steering gear and cause leakage Remove the clamps and the two front suspension stee...

Page 771: ...eering gears equipped with travel restrictors 9 NOTE Some steering gears may contain one or two rack travel restrictors on each side of the steering gear The restrictors are split washers and can be removed if necessary Remove the travel restrictors Discard any travel restrictors that are heavily worn All steering gears 10 Remove the steering gear from the special tools Assembly All steering gears...

Page 772: ... the front suspension steering ball stud dust seals If the front suspension steering ball stud dust seals are damaged this will allow contamination into the steering gear and cause leakage Install the front suspension steering ball stud dust seals and clamps Position the front suspension steering ball stud seals and steering gear rack tubes as shown Install new front suspension steering ball stud ...

Page 773: ...hreads 7 Remove the steering gear from the special tools 8 Install the steering gear mounting bracket housing insulators Install new steering gear mounting bracket housing insulators as necessary The large end of the metal sleeve must be positioned downward Check that the mounting surfaces are clean and free of foreign material ...

Page 774: ......

Page 775: ... FOAZ 19584 A ESA M1C232 A Torque Specifications Description Nm lb ft lb in Lock cylinder housing screws 22 17 Steering column lower bearing retainer bolts 9 80 Ignition switch screws 6 53 Multi function switch screws 3 27 Steering wheel bolt 38 28 Steering column retaining nuts 15 12 Intermediate shaft coupler to steering column shaft bolt 25 19 ...

Page 776: ...ION AND OPERATION Steering Column SECTION 211 04 Steering Column 2003 Mustang Workshop Manual Item Part Number Description 1 043B13 Driver air bag module 2 N804385 S100 Steering wheel bolt 3 3600 Steering wheel ...

Page 777: ...29 Shroud retaining screws 22 3D544 Release lever 23 3B661 Lock actuator lever RH 24 N805856 Lock actuator lever pin 25 3D653 Lock actuator lever LH 26 3B664 Lock lever spring 2 req d 27 14A099 Wiring shield 28 3D655 Lock lever spring return 29 3E715 Lock lever upper actuator 30 3E696 Lock spring shaft 31 11572 Ignition switch 32 N806423 S56 Steering column mounting lower nuts 33 N806584 Screw 34 ...

Page 778: ...e upper attachments are through plastic shear modules that separate from the main casting during collapse A clip and washer are attached to the shear modules to reduce steering column shake and to assist in installation of the steering column 45 N621906 Nut 46 N803942 Bolt 47 3A525 Intermediate shaft coupling 48 11A128 Ignition key warning switch terminal 49 N806583 Bearing housing retaining screw...

Page 779: ......

Page 780: ...ce only Remove from vehicle prior to road use Failure to remove could result in injury and possible violation of vehicle safety standards 1 WARNING To avoid accidental deployment and possible personal injury the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system SRS components and before servicing replacing adjusting or striki...

Page 781: ...g clips and remove the steering column opening lower finish panel 3 Remove the steering column opening lower reinforcement 1 Remove the bolts 2 Remove the steering column opening lower reinforcement 4 Pushing in on the release tab disconnect the clockspring electrical connector at the base of the steering column 5 Attach the restraint system diagnostic tool to the vehicle harness side of the clock...

Page 782: ... the right hand A C register duct Remove the two screws retaining the duct to the A C register Separate the A C duct at the air plenum and remove the duct 8 Disconnect the passenger air bag module 9 Attach the restraint system diagnostic tool to the vehicle harness side of the passenger air bag electrical connector ...

Page 783: ...ait at least one minute For additional information refer to Section 414 01 Reactivation WARNING To reduce the risk of serious personal injury read and follow all warnings cautions and notes at the beginning of the deactivation procedure 1 Disconnect the battery ground cable and wait at least one minute For additional information refer to Section 414 01 2 Remove the restraint system diagnostic tool...

Page 784: ...the clockspring electrical connector 7 Connect the clockspring electrical connector at the base of the steering column 8 Install the steering column opening lower reinforcement 1 Position the steering column opening lower reinforcement 2 Install the bolts 9 Install the steering column opening lower finish panel 1 Align the steering column opening lower finish panel and push in seating the retainin...

Page 785: ...ic tool is for restraint system service only Remove from vehicle prior to road use Failure to remove could result in injury and possible violation of vehicle safety standards With all the restraint system diagnostic tools removed prove out the supplemental restraint system SRS For additional information refer to Section 501 20B ...

Page 786: ... ignition switch lock cylinder 11582 1 Insert the ignition key and turn to the RUN position 2 Using a 1 8 inch drift press the ignition switch lock cylinder release pin through the access hole while pulling out the ignition switch lock cylinder 3 To install reverse the removal procedure Verify ignition switch lock cylinder operation SECTION 211 04 Steering Column 2003 Mustang Workshop Manual ...

Page 787: ......

Page 788: ...on refer to Supplemental Restraint System SRS Deactivation and Reactivation in this section 3 WARNING To reduce the risk of serious personal injury read and follow all warnings cautions notes and instructions in the steering wheel removal and installation procedure Remove the steering wheel assembly For additional information refer to Wheel in this section 4 Twist off the cap from the ignition swi...

Page 789: ...switch lock cylinder breaks loose Remove and discard the ignition switch lock cylinder and clean the drill shavings from the steering column 6 Remove the bearing retainer 7 Remove the bearing and gear Thoroughly clean all drill shavings from the steering column and inspect it for damage 8 To install reverse the removal procedure Install a new ignition switch lock cylinder Verify ignition switch lo...

Page 790: ... read and follow all warnings cautions notes and instructions in the reactivation procedure Reactivate the supplemental restraint system SRS For additional information refer to Supplemental Restraint System SRS Deactivation and Reactivation in this section ...

Page 791: ...ation procedure Deactivate the supplemental restraint system SRS For additional information refer to Supplemental Restraint System SRS Deactivation and Reactivation in this section 4 WARNING To avoid risk of serious personal injury follow all warnings cautions notes and instructions in the driver air bag removal and installation procedure Remove the driver air bag module For additional information...

Page 792: ...al procedure 9 WARNING To avoid the risk of serious personal injury follow all warnings cautions notes and instructions at the beginning of the reactivation procedure Reactivate the supplemental restraint system SRS For additional information refer to Supplemental Restraint System SRS Deactivation and Reactivation in this section ...

Page 793: ...r additional information refer to Supplemental Restraint System SRS Deactivation and Reactivation in this section 3 WARNING To reduce the risk of serious personal injury follow all warnings cautions notes and instructions in the clockspring removal and installation procedure Remove the clockspring 14A664 For additional information refer to Section 501 20B 4 Remove the multi function switch 13K359 ...

Page 794: ...om the steering column 7 Disconnect the electrical connector Vehicles with manual transmission 8 Remove the nuts and the steering column Discard the nuts Vehicles with automatic transmission 9 Remove the nuts and lower the steering column Discard the nuts ...

Page 795: ...ocedure 12 WARNING To avoid the risk of serious personal injury follow all warnings cautions notes and instructions at the beginning of the reactivation procedure Reactivate the supplemental restraint system SRS For additional information refer to Supplemental Restraint System SRS Deactivation and Reactivation in this section ...

Page 796: ......

Page 797: ...l information refer to Section 501 20B NOTE Discard the steering column shaft pinch bolt and the lower intermediate shaft to steering gear pinch bolt Do not reuse install new bolts Remove and discard the steering column shaft pinch bolt and disconnect the intermediate from the coupling 2 Raise and support the vehicle For additional information refer to Section 100 02 3 Remove the pinch bolt 4 Disc...

Page 798: ...5 To install reverse the removal procedure ...

Page 799: ...s rotated the clockspring must be removed and recentered For additional information refer to Section 501 20B NOTE Discard the steering column shaft pinch bolt and the lower intermediate shaft to steering gear pinch bolt upon removal Do not reuse install new bolts Remove the pinch bolts and disconnect the coupling from the column 2 Remove the coupling 3 To install reverse the removal procedure SECT...

Page 800: ......

Page 801: ...ring column 3C529 For additional information refer to Column in this section 2 Remove the ignition switch 11572 1 Remove the screws 2 Remove the ignition switch 3 CAUTION Carefully note the position of the steering column lock gear bearing and retainer prior to removal Remove the bearing retainer 3D681 SECTION 211 04 Steering Column 2003 Mustang Workshop Manual Special Tool s Steering Column Locki...

Page 802: ...move the lock housing bearing 3E700 5 Remove the lock gear 3E717 6 Remove the sensor ring 1 Remove the lower bearing spring 2 Remove the sensor ring 7 Remove the lower bearing tolerance ring from the shaft ...

Page 803: ... under tension and can come out with great force Remove the lock cylinder housing and shaft assembly from the actuator housing 3F723 1 Pry up on the lock actuator lever LH 3D653 using a shop fabricated tool 2 Remove the position spring 3D655 10 Remove the turn indicator cancel cam ...

Page 804: ...20 13 Remove the bearing sleeve 3518 14 Remove the lower bearing tolerance ring 3L539 1 Slide the steering column shaft in toward the lock cylinder housing 3511 2 Slide the steering column bearing tolerance ring from the steering column shaft and remove the shaft ...

Page 805: ...e a suitable punch to remove the bearing from the lock cylinder housing 17 Remove the lower bearing and sleeve 18 Remove the lower bearing retainer 3D681 1 Remove the three bolts 2 Remove the lower bearing retainer 19 Remove the upper lock lever actuator 3E715 and the lower lock lever actuator ...

Page 806: ...ve the ignition lock cylinder lockout lever 21 Remove the lock actuator lever return spring 22 Using a pin punch remove the pin and lock actuator lever 23 Using a pin punch remove the pin and locking lever cam ...

Page 807: ...E Do not remove the tilt lock levers if not required Using a pin punch remove the pin tilt locking levers and springs Assembly 1 Install the locking lever cam and pin 2 Install the lock actuator lever and pin ...

Page 808: ... side If necessary install the springs and lock levers 1 Install the spring and lever on the left hand side Use a pin punch to hold the compressed spring in position 2 Install the spring and lever on the right hand side Use the pivot pin to hold the compressed spring in position 3 Tap the pin through the levers pushing out the pin punch until flush with the housing ...

Page 809: ...ition Lock Grease F0AZ 19584 A or equivalent meeting Ford specification ESA M1C232 A 2 Install the lock lever actuators 7 Install the lower bearing retainer 1 Position the lower bearing retainer 2 Install the three bolts 8 NOTE The UP position of the bearing must be facing forward ...

Page 810: ...ring column bearing so that the inner race is visible when installed NOTE Use an appropriate bearing installer or socket Install the bearing in the lock cylinder housing Item Part Number Description 1 Outer race 2 3517 Bearing in the UP position 3 Ball 4 Inner race ...

Page 811: ...10 CAUTION Install the steering column bearing so that the inner race is visible when installed Item Part Number Description 1 Outer race 2 Bearing in the UP position 3 Ball 4 Inner race ...

Page 812: ...priate bearing installer or socket Install the bearing in the lock cylinder housing Item Part Number Description 1 Bearing slot 2 3511 Lock cylinder housing 3 Outer race 4 Bearing in the UP position 5 Ball 6 Inner race ...

Page 813: ...11 Position the shaft in the steering column lock cylinder housing Install the bearing tolerance ring on the steering column shaft 12 Install the bearing sleeve 13 Install the upper bearing spring ...

Page 814: ...rews with Ignition Lock Grease F0AZ 19584 A or equivalent meeting Ford specification ESA M1C232 A 16 Place two nuts or spacers to hold the lock levers away from the actuator housing 17 NOTE Lubricate the lock cylinder housing pivot bushings with Ignition Lock Grease F0AZ 19584 A or equivalent meeting Ford specification ESA M1C232 A ...

Page 815: ...spring Align the lock cylinder housing bushings with the pivot screws and tighten the screws Using a long thin screwdriver remove the nuts installed under the lock levers 18 Install the bearing tolerance ring 19 Install the sensor ring 1 Install the sensor ring 2 Install the lower bearing spring 20 Install the ignition switch Align the ignition switch with the slot and index mark on the actuator h...

Page 816: ...ting Ford specification ESA M1C232 A to coat the lock gear 22 Install the lock housing bearing The narrow section of the keyhole should be in the one o clock position with the tab inboard at the three o clock position and rotate it counterclockwise Lubricate the lock housing bearing with Ignition Lock Grease F0AZ 19584 A or equivalent meeting Ford specification ESA M1C232 A ...

Page 817: ...ousing 24 Install the turn indicator cancel cam 25 WARNING To avoid risk of serious personal injury follow all warnings cautions notes and instructions in the steering column removal and installation procedure Install the steering column For additional information refer to Column in this section ...

Page 818: ......

Page 819: ...lumn Switches 2003 Mustang Workshop Manual Torque Specifications Description Nm lb ft lb in Ignition switch screws 6 53 Instrument panel reinforcement screws 9 80 Instrument panel steering column cover screws 9 80 Key release button bolt 5 44 ...

Page 820: ...tifunction switch is mounted to the LH side of the steering column and controls the turn signals hazard flasher windshield wiper washer control and headlamp dimmer flash to pass The key release button is equipped with manual transmissions only The ignition switch is mounted below the steering column and is activated by rotating the key lock cylinder on the steering column SECTION 211 05 Steering C...

Page 821: ...e concern remains after the inspection connect the scan tool to the data link connector DLC located beneath the instrument panel and select the vehicle to be tested from the scan tool menu If the scan tool does not communicate with the vehicle check that the program card is correctly installed SECTION 211 05 Steering Column Switches 2003 Mustang Workshop Manual Special Tool s Worldwide Diagnostic ...

Page 822: ...M REFER to Section 413 06 B1218 Horn Relay Coil Circuit Short to Vbatt GEM REFER to Section 413 06 B1312 Lamp Headlamp Input Circuit Short to Battery GEM REFER to Section 417 01 B1317 Battery Voltage High GEM REFER to Section 414 00 B1318 Battery Voltage Low GEM REFER to Section 414 00 B1322 Driver Door Ajar Circuit Short to Ground GEM REFER to Section 417 02 B1330 Passenger Door Ajar Circuit Shor...

Page 823: ...Sense Circuit Failure GEM REFER to Section 501 16 B1448 Wiper Park Sense Circuit Short to Battery GEM REFER to Section 501 16 B1450 Wiper Wash Delay Switch Circuit Failure GEM REFER to Section 501 16 B1453 Wiper Wash Delay Switch Circuit Short to Ground GEM REFER to Section 501 16 B1458 Wiper Washer Pump Motor Relay Circuit Failure GEM REFER to Section 501 16 B1460 Wiper Washer Pump Motor Relay Co...

Page 824: ...t A The ignition switch is inoperative BJB Fuse IGN SW 40A Ignition switch Circuitry Go To Pinpoint Test B No power in ACC Ignition switch Circuitry Go To Pinpoint Test C No power in RUN Ignition switch Circuitry Go To Pinpoint Test D No power in START Ignition switch Circuitry Go To Pinpoint Test E The multifunction switch hazard switch does not operate correctly Multifunction switch Carry out th...

Page 825: ...ce between the GEM C201b pin 2 circuit 397 BK WH harness side and ground Is the resistance less than 5 ohms Yes GO to A3 No REPAIR the circuit s in question TEST the system for normal operation A3 CHECK CIRCUIT 397 BK WH FOR SHORT TO POWER Measure the voltage between GEM C201b pin 2 circuit 397 BK WH harness side and ground Is any voltage present Yes REPAIR the circuit TEST the system for normal o...

Page 826: ...in B5 Circuit 1050 LG VT harness side and ground Is the voltage greater than 10 volts Yes INSTALL a new ignition switch REFER to Ignition Switch TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation Test Step Result Action to Take D1 CHECK THE IGNITION SWITCH Carry out the ignition switch component test REFER to Wiring Diagrams Cell 149 Component Testing I...

Page 827: ...R the circuit in question TEST system for normal operation E2 CHECK THE CONTINUITY OF THE IGNITION SWITCH Carry out the ignition switch continuity test REFER to Wiring Diagrams Cell 149 Component Testing Does the ignition switch test OK Yes GO to E3 No INSTALL a new ignition switch REFER to Ignition Switch TEST the system for normal operation E3 CHECK CIRCUIT 16 RD LB AND CIRCUIT 33 WH PK Connect ...

Page 828: ......

Page 829: ...o RUN position 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder 3 Remove the tilt wheel handle 4 Remove the upper and lower steering column shrouds 1 Remove the screws 2 Remove the upper and lower steering column shrouds 5 Remove the multifunction switch 1 Remove the screws SECTION 211 05 Steering Column Switches 2003 Mustang Wor...

Page 830: ...Installation 1 NOTE When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km 10 mi or more to relearn the strategy To install reverse the removal procedure ...

Page 831: ...rument panel steering column cover 3 Remove the instrument panel reinforcement 1 Remove the screws 2 Remove the instrument panel reinforcement 4 Disconnect the ignition switch electrical connector 1 Loosen the bolt 2 Disconnect the ignition switch electrical connector 5 NOTE Ignition switch should be in the OFF position SECTION 211 05 Steering Column Switches 2003 Mustang Workshop Manual ...

Page 832: ... Installation 1 NOTE When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km 10 mi or more to relearn the strategy To install reverse the removal procedure ...

Page 833: ......

Page 834: ...ition 2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch lock cylinder 3 Remove the tilt wheel handle 4 Remove the upper and lower steering column shrouds 1 Remove the screws 2 Remove the upper and lower steering column shrouds 5 Remove the key release button 1 Remove the key release button bolt SECTION 211 05 Steering Column Switches 2003 Musta...

Page 835: ... 1 NOTE When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km 10 mi or more to relearn the strategy To install reverse the removal procedure ...

Page 836: ...kshop Manual General Specifications Item Specification Lubricants and Sealants SAE 5W 20 Premium Synthetic Blend Motor Oil XO 5W20 QSP WSS M2C153 H Diesel engine oil Refer to owner literature Gasoline Engine Oil Dye 164 R3705 ESE M99C103 B1 Threadlock 262 E2FZ 19554 B WSK M2G351 A6 ...

Page 837: ...al information refer to Section 303 08 an evaporative emission control system For additional information refer to Section 303 13 Some engines incorporate a fail safe cooling system Refer to the appropriate section in Group 303 for the procedure The engine fuel system ignition system emissions system and exhaust system all affect exhaust emission levels and must be maintained according to the maint...

Page 838: ...ssion Tester 134 R0212 or equivalent Dial Indicator Gauge Adapter 303 007 TOOL 6565 AB or equivalent Dial Indicator Gauge with Holding Fixture 100 002 TOOL 4201 C or equivalent Engine Cylinder Leak Detection Air Pressurization Kit 014 00708 or equivalent Oil Pressure Gauge 303 088 T73L 6600 A UV Leak Detector Kit 164 R0756 or equivalent Vacuum Pressure Tester 164 R0253 or equivalent ...

Page 839: ...valent ESE M99C103 B1 Engine Oil Refer to owner literature Visual Inspection Chart Mechanical Engine coolant leaks Engine oil leaks Fuel leaks Damaged or severely worn parts Loose mounting bolts studs and nuts Symptom Chart Condition Possible Sources Action Difficult starting Damaged ignition system Refer to the appropriate section in Group 303 for the procedure REFER to the Powertrain Control Emi...

Page 840: ...ED manual Malfunctioning or damaged fuel system Refer to the appropriate section in Group 303 for the procedure REFER to the Powertrain Control Emissions Diagnosis PC ED manual Damaged valve tappet or lash adjuster INSTALL a new valve tappet or lash adjuster Damaged valve tappet guide or lash adjuster INSTALL a new valve tappet guide or valve tappet Incorrect valve to valve seat contact REPAIR or ...

Page 841: ... piston ring groove INSTALL a new piston and piston pin Worn piston or cylinder REPAIR or INSTALL a new piston or cylinder block Engine noise Leaking exhaust system REPAIR exhaust leakage Incorrect drive belt tension REFER to Section 303 05 Malfunctioning generator bearing Refer to the appropriate section in Group 414 for the procedure Malfunctioning water pump bearing REFER to Section 303 03A Mal...

Page 842: ...r Excessive valve tappet or lash adjuster clearance ADJUST clearance or INSTALL a new valve tappet guide or valve tappet Broken valve spring 6513 INSTALL a new valve spring Excessive valve guide clearance ADJUST clearance or INSTALL a new valve guide 6510 or valve Insufficient power Malfunctioning or damaged ignition system Refer to the appropriate section in Group 303 for the procedure REFER to t...

Page 843: ...yellow or orange area will identify the leak For extremely small leaks several hours may be required for the leak to appear Leakage Points Underhood Examine the following areas for oil leakage valve cover gaskets Slipping transmission Refer to the appropriate section in Group 307 for the procedure Malfunctioning valve tappet or lash adjuster INSTALL a new valve tappet or lash adjuster Damaged valv...

Page 844: ...6 or pipe plugs at the end of oil passages Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected when using the dye method Compression Test Compression Gauge Check 1 Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery 10655 is correctly charged Operate the vehicle until the engine is at normal op...

Page 845: ...50 psi 1586 kPa 230 psi 1186 kPa 172 psi 979 kPa 142 psi 738 kPa 107 psi 1186 kPa 172 psi 889 kPa 129 psi 1303 kPa 202 psi 1041 kPa 151 psi 1600 kPa 232 psi 1200 kPa 174 psi 933 kPa 144 psi 745 kPa 109 psi 1200 kPa 174 psi 903 kPa 131 psi 1407 kPa 204 psi 1055 kPa 153 psi 1055 kPa 153 psi 1207 kPa 175 psi 1007 kPa 146 psi 758 kPa 110 psi 1214 kPa 176 psi 910 kPa 132 psi 1420 kPa 206 psi 1062 kPa 1...

Page 846: ...er the noise will be evident at the spark plug hole of the cylinder into which the air is leaking Cracks in the cylinder block or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator 8005 Oil Consumption Test The following diagnostic procedure is used to determine the source of excessive internal oil consumption 1 NOTE Oil use is normally greater during the...

Page 847: ...he oil level dipstick and record Measure the distance between the two scribe marks and record Divide the first measurement by the second Divide the distance driven during the oil test by the result This quantity is the approximate oil consumption rate in kilometers per liter or in miles per quart h If the oil consumption rate is unacceptable go to Step 7 7 Check the positive crankcase ventilation ...

Page 848: ...tudy of the vacuum gauge reading while the engine is idling will help pinpoint trouble areas Always conduct other appropriate tests before arriving at a final diagnostic decision Vacuum gauge readings although helpful must be interpreted carefully Most vacuum gauges have a normal band indicated on the gauge face The following are potential gauge readings Some are normal others should be investigat...

Page 849: ...l pulsation of the needle can occur 13 INTAKE LEAK A low steady reading can be caused by an intake manifold or throttle body gasket leak 14 BLOWN HEAD GASKET A regular drop of fair magnitude can be caused by a blown head gasket or warped cylinder head to cylinder block surface 15 RESTRICTED EXHAUST SYSTEM When the engine is first started and is idled the reading may be normal but as the engine rpm...

Page 850: ...eeds on the highway where the condensation and fuel boil off The next time the engine oil is checked it may appear that a liter quart of oil was used in about 160 km 100 miles This perceived 160 km 100 miles per liter quart oil consumption rate causes customer concern even though the actual overall oil consumption rate is about 2 400 km 1 500 miles per liter quart Make sure the selected engine oil...

Page 851: ...en or damaged parts Valve Train Analysis Engine Off Push Rods Check for bent push rods 6565 and restricted oil passage Valve Train Analysis Valve Springs Check for broken or damaged parts Valve Train Analysis Engine Off Valve Spring Retainer and Valve Spring Retainer Keys Check for correct seating of the valve spring retainer key 6518 on the valve stem and in valve spring retainer 6514 Check for c...

Page 852: ...eck the lift of each camshaft lobe in consecutive order and make a note of the readings 1 Remove the valve covers 2 Remove the spark plugs 3 Install the Dial Indicator Gauge with Holding Fixture so the rounded tip of indicator is on top of the camshaft lobe and on the same plane as the valve tappet 4 Rotate the crankshaft using a breaker bar and socket attached to the crankshaft pulley retainer bo...

Page 853: ...rting circuit Crank the engine with ignition switch in OFF position Bump crankshaft over until valve tappet is on base circle of camshaft lobe At this point valve tappet will be in its lowest position If checking during engine assembly turn crankshaft using a socket or ratchet 6 Zero the dial indicator Continue to rotate crankshaft slowly until valve tappet is in fully raised position highest indi...

Page 854: ...an be caused by an obstruction such as dirt or chips that prevent the check valve from closing or a broken check valve spring A tappet with a leakdown time out of specification can cause tappet noise If no other cause for noisy valve tappets can be found the leakdown rate should be checked and new valve tappets installed if found to be out of specification Assembled valve tappets can be tested wit...

Page 855: ...e procedure NOTE If a component fails to meet the specifications it is necessary to install a new component or refinish If the component can be refinished wear limits are provided as an aid to making a decision A new component must be installed for any component that fails to meet specifications and cannot be refinished Inspect the timing chain belt and the sprockets Install new components as nece...

Page 856: ...aning 1 Clean all parts thoroughly Make sure all oil passages are open 2 Make sure oil passage in the push rod valve tappet end of the rocker arm 6564 is open SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 857: ...sible damage may occur 1 Inspect the rocker arm push rod bore for nicks scratches scores or scuffs Install new components as necessary Refer to the appropriate section in Group 303 for the procedure 2 Inspect the pad at the valve end of the rocker arm for indications of scuffing or abnormal wear If the pad is grooved install a new rocker arm Refer to the appropriate section in Group 303 for the pr...

Page 858: ...EDURES Push Rods Cleaning 1 Clean the push rods 6565 in a suitable solvent Blow out the oil passage in the push rods with compressed air SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 859: ...on in Group 303 for the procedure The push rods can be checked for straightness while they are installed in the engine by rotating them with the valve closed They also can be checked using a Dial Indicator with Bracketry 2 If the push rod is bent beyond specifications install a new push rod Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Informa...

Page 860: ...re each camshaft journal diameter in two directions If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 861: ...e camshaft journals must meet specifications before checking camshaft journal clearance Measure each camshaft bearing 6261 in two directions Subtract the camshaft journal diameter from the camshaft bearing diameter SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 862: ......

Page 863: ...E Do not turn the camshaft while carrying out this procedure Position the camshaft bearing cap and install the bolts Refer to the appropriate section in Group 303 for the procedure 3 Use Plastigage to verify the camshaft journal clearance If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General ...

Page 864: ......

Page 865: ...rear of the cylinder block 4 Zero the indicator 5 Move the camshaft to the front of the cylinder block Note and record the camshaft end play If the camshaft end play exceeds specifications install a new camshaft thrust plate Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual Special Tool s Dial Indicator Gau...

Page 866: ......

Page 867: ...the cylinder head Note and record the camshaft end play If camshaft end play exceeds specifications install new camshaft and recheck end play Refer to the appropriate section in Group 303 for the procedure If camshaft end play exceeds specification after camshaft installation install a new cylinder head Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System Ge...

Page 868: ......

Page 869: ...n the contact area Minor pitting is acceptable outside the contact area If excessive pitting or damage is present install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 870: ...shaft and subtract the lowest indicator reading from the highest indicator reading to figure the camshaft lobe lift Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual Special Tool s Dial Indicator Gauge with Holding Fixture 100 002 TOOL 4201 C or equivalent ...

Page 871: ...ndicator reading from the highest indicator reading For additional information refer to the specification chart in the appropriate engine section If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual Special Tool s Dial Indicator Gauge with Holding Fix...

Page 872: ......

Page 873: ...ournal diameters in at least two directions Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 874: ... least two directions at each end of the main bearing journal Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 875: ...bearing surface 3 NOTE Do not turn the crankshaft while carrying out this procedure Install and remove the crankshaft main bearing cap 4 Verify the crankshaft journal clearance Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System Genera...

Page 876: ......

Page 877: ...rankshaft to the front of the cylinder block Note and record the crankshaft end play If crankshaft end play exceeds specifications install a new crankshaft thrust washer 6334 or crankshaft thrust main bearing 6337 Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual Special Tool s Dial Indicator Gauge with Hol...

Page 878: ......

Page 879: ...3 for the procedure Rotate the crankshaft and subtract the lowest dial indicator reading from the highest dial indicator reading to figure the crankshaft runout If it is out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual Special Tool s Dial Indicator G...

Page 880: ......

Page 881: ...ecting rod journal The difference in the measurements from one end to the other is the taper Verify measurement is within the wear limit Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manu...

Page 882: ...avel in two directions as indicated Verify the cylinder bore is within the wear limit The difference indicates the cylinder bore taper Bore the cylinder to the next oversize Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 883: ...irections The difference is the out of round Verify the out of round is within the wear limit and bore the cylinder to the next oversize limit Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 884: ...s and the 4 tops of the pistons If wear marks scores or glazing is found on the piston skirt check for a bent or twisted connecting rod 2 Use the Piston Ring Groove Scraper to clean the piston ring grooves Make sure the oil ring holes are clean SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual Special Tool s Scraper Piston Ring Groove 303 D033 D81L 6002 D or equivalent ...

Page 885: ......

Page 886: ...ction NOTE Piston and piston pins are a matched set and should not be interchanged Measure the piston pin bore diameter in two directions on each side Verify the diameter is within specification If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 887: ......

Page 888: ... pin at the point indicated Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 889: ...Piston to Cylinder Bore Clearance 1 Subtract the piston diameter from the cylinder bore diameter to find the piston to cylinder bore clearance SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 890: ...For precision fit new pistons are divided into three categories within each size range based on their relative position within the range A paint spot on the new pistons indicates the position within the size range Choose the piston with the correct paint color Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manu...

Page 891: ......

Page 892: ... another NOTE Cylinder bore must be within specification for taper and out of round 1 Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel 2 Use a feeler gauge to measure the top piston ring end gap and the second piston ring end gap Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang W...

Page 893: ......

Page 894: ...r 2 Measure the piston ring to groove clearance Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 895: ......

Page 896: ...n Verify the diameter is within specification Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 897: ...onnecting rod large end is a matched set The connecting rod cap must be installed on the original connecting rod in the original position Do not reverse the cap Parts are not interchangeable Mark and separate the parts and clean with solvent Clean the oil passages SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 898: ...e connecting rod bore out of round Verify the out of round is within specification Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 899: ...uipped Verify the diameter is within specification Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 900: ...fixture manufacturer Verify the bend measurement is within specification Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 901: ...he fixture manufacturer Verify the measurement is within specification Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 902: ... piston Verify the measurement is within specification Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 903: ... then remove the connecting rod bearing cap 4 Measure the Plastigage to get the connecting rod bearing journal clearance The Plastigage should be smooth and flat A changing width indicates a tapered or damaged connecting rod or connecting rod bearing Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate ...

Page 904: ......

Page 905: ...aft Verify the measurement is within specification Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 906: ...pection Push rod engines 1 Inspect the roller for flat spots or scoring If any damage is found inspect the camshaft lobes and valve tappet for damage OHC engines SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 907: ......

Page 908: ...ion Push rod engines 1 Inspect the hydraulic valve tappet and roller for damage If any damage is found inspect the camshaft lobes and valves for damage OHC engines SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 909: ......

Page 910: ...shown Verify the diameter is within specification Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 911: ... the upper surface of the valve guide 2 Move the Valve Guide Clearance Gauge toward the indicator and zero the indicator Move the Valve Guide Clearance Gauge away from the indicator and note the reading The reading will be DOUBLE the valve stem to valve guide clearance Valves with oversize stems will need to be installed if out of specification SECTION 303 00 Engine System General Information 2003...

Page 912: ......

Page 913: ...1 the end of the stem for grooves or scoring 2 the valve face and the edge for pits grooves or scores 3 the valve head for signs of burning erosion warpage and cracking 4 the valve margin for wear SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 914: ...indicated Refer to the appropriate section in Group 303 for the procedure 2 If the valve guide is not within specifications ream the valve guide and install a valve with an oversize stem or remove the valve guide and install a new valve guide SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 915: ...URES Valve Guide Reaming 1 Use a hand reaming kit to ream the valve guide 2 Reface the valve seat 3 Clean the sharp edges left by reaming SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 916: ...gth of each valve spring Refer to the appropriate section in Group 303 for the procedure If out of specification install new components Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 917: ... valve spring Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 918: ...spring Turn the valve spring and observe the space between the top of the valve spring and the square Install a new valve spring if out of square Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 919: ...ng length Refer to the appropriate section in Group 303 for the procedure If out of specification install new components as necessary Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual Special Tool s Pressure Gauge Valve Clutch Spring 303 006 TOOL 6513 DD or equivalent ...

Page 920: ......

Page 921: ...k valve clearance 1 Check the valve head and seat Check valve angles Check margin width Refer to the appropriate section in Group 303 for the procedure Be sure margin width is within specification 2 Inspect for abnormalities on the valve face and seat SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 922: ...t width Measure the exhaust valve seat width Recheck the valve spring installed length after the seats have been ground and shim the valve springs as necessary to achieve the correct installed spring length Refer to the appropriate section in Group 303 for the procedure SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 923: ...GENERAL PROCEDURES Valve Seat Runout 1 Use the Valve Seat Runout Gauge to check valve seat runout SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 924: ...e and a feeler gauge to inspect the cylinder head for flatness If the cylinder head is distorted install a new cylinder head SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual Special Tool s Straight Edge 303 D039 D83L 4201 A or equivalent ...

Page 925: ...ur Clean the cylinder bores with soap or detergent and water 2 Thoroughly rinse with clean water and wipe dry with a clean lint free cloth 3 Use a clean lint free cloth and lubricate the cylinder bores Use clean engine oil meeting Ford specification SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 926: ... the plug Coat the cylinder block core plug and bore lightly with Threadlock 262 and install the cylinder block core plug Cup Type 4 CAUTION Use care during this procedure so as not to disturb or distort the cup sealing surface CAUTION When installed the flanged edge must be below the chamfered edge of the bore to effectively seal the bore Use a tool suitable to seat the cup type cylinder block co...

Page 927: ...TION Do not contact the crown when installing an expansion type cylinder block core plug This could expand the plug before seating and result in leakage Use tool suitable to seat the expansion type cylinder block core plug ...

Page 928: ...park Plug Hole Thread Repair 1 There is no authorized repair for spark plug hole threads If the threads are damaged install a new cylinder head SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 929: ...e oil entering the combustion chamber through worn rings and pistons excessive valve to guide clearance or worn or loose bearings Correct the oil leak concern Install a new spark plug 3 Inspect for carbon fouling Look for black dry fluffy carbon deposits on the insulator tips exposed shell surfaces and electrodes caused by a spark plug with an incorrect heat range dirty air cleaner too rich a fuel...

Page 930: ...rrect ignition timing wrong type of fuel or the unauthorized installation of a heli coil insert in place of the spark plug threads Install a new spark plug 6 Inspect for overheating identified by a white or light gray spots and with bluish burnt appearance of electrodes This is caused by engine overheating wrong type of fuel loose spark plugs spark plugs with an incorrect heat range low fuel pump ...

Page 931: ...7 Inspect for fused deposits identified by melted or spotty deposits resembling bubbles or blisters These are caused by sudden acceleration Clean the spark plug ...

Page 932: ...on 1 Place a straight edge across the exhaust manifold flanges and check for warping with a feeler gauge SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual Special Tool s Straight Edge 303 D039 D83L 4201 A or equivalent ...

Page 933: ...ratering fatigue failure 2 Spot polishing incorrect seating 3 Imbedded dirt engine oil 4 Scratching dirty engine oil 5 Base exposed poor lubrication 6 Both edges worn journal damaged 7 One edge worn journal tapered or bearing not seated SECTION 303 00 Engine System General Information 2003 Mustang Workshop Manual ...

Page 934: ......

Page 935: ...m 0 007 in Combustion chamber volume 61 5 64 5 cc Valve arrangement front to rear Valve guide bore diameter 7 015 7 044 mm 0 276 0 277 in Valve stem diameter intake 6 955 6 988 mm 0 2738 0 2751 in Valve stem diameter exhaust 6 929 6 962 mm 0 2728 0 2741 in Valve stem diameter oversize intake 9 075 9 055 mm 0 3573 0 3565 in Valve stem diameter oversize exhaust 9 063 9 043 mm 0 3568 0 3560 in Valve ...

Page 936: ...meter 52 082 52 108 mm 2 0505 2 0515 in Camshaft journal bore inside diameter No 1 55 689 55 664 mm 2 192 2 191 in Camshaft journal bore inside diameter No 2 and No 3 55 308 55 283 mm 2 177 2 176 in Camshaft journal bore inside diameter No 4 55 684 55 664 mm 2 192 2 191 in Camshaft journal to bearing clearance 0 025 0 076 mm 0 001 0 003 in Runout 0 05 mm 0 002 in runout of No 2 or No 3 relative to...

Page 937: ...bottom in gauge 0 3 0 55 mm 0 0118 0 0217 in Piston ring end gap oil ring steel rail in gauge 0 15 0 65 mm 0 0059 0 0256 in Piston ring groove width compression top 1 54 1 52 mm 0 0606 0 0598 in Piston ring groove width compression bottom 1 54 1 52 mm 0 0606 0 0598 in Piston ring groove width compression oil 3 05 3 03 mm 0 1200 0 1193 in Piston ring width compression top and bottom 1 460 1 490 mm ...

Page 938: ...er head bolts 10 89 LH valve cover to cylinder head stud bolts 10 89 EGR tube to exhaust manifold nut 40 30 RH valve cover to cylinder head bolts 10 89 RH valve cover to cylinder head stud bolts 10 89 Coolant recovery reservoir to cylinder head stud bolts 10 89 Coolant recovery reservoir to bracket bolts 5 44 Crankshaft pulley bolt 160 118 Camshaft position sensor bolts 3 27 Camshaft synchronizer ...

Page 939: ...unt stud nut 27 20 Engine ground strap to motor mount nut 27 20 Motor mount to motor mount bracket bolts 70 52 RH motor mount to motor mount bracket nut 70 52 Hood ground strap to hood hinge bolt 12 9 Hood hinge nuts 12 9 Generator mounting bracket 25 18 Power steering pump bracket nuts 8 71 Power steering pump bolts 25 18 Valve tappet guide plate bolts 12 9 Generator positive cable nut 10 89 Powe...

Page 940: ...a Refer to the procedure in this section b Advance one half turn after gasket contacts the sealing surface Cylinder head bolts a Crankshaft main bearing bolts and studs a Connecting rod cap bolts a ...

Page 941: ...istributorless ignition system a multiport sequential fuel injection SFI system overhead valves hydraulic valve tappets for automatic lash adjustment connecting rod parting faces that are unique with an interference fit an engine dynamic balance shaft SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual ...

Page 942: ...N 303 01A Engine 3 8L 2003 Mustang Workshop Manual Item Part Number Description 1 9D477 EGR valve to exhaust manifold tube 2 6C342 Crankcase ventilation hose 3 6582 Valve cover RH 4 12405 Spark plug 5 6049 Cylinder head RH 6 6582 Valve cover LH 7 6766 Oil fill cap 8 6758 Crankcase ventilation tube ...

Page 943: ...ing retainer 16 6513 Valve spring 17 6A517 Valve stem seal 18 611497 Bolt 19 6049 Cylinder head LH 20 9448 Exhaust manifold gasket LH 21 17A084 Engine lifting eye 22 6754 Oil level indicator tube 23 9430 Exhaust manifold LH 24 6507 Intake valve 25 6505 Exhaust valve 26 6051 Head gasket LH 27 6051 Head gasket RH 28 9448 Exhaust manifold gasket RH 29 9430 Exhaust manifold RH 30 17A084 Engine lifting...

Page 944: ...8507 Water pump housing gasket 3 12A362 Camshaft synchronizer 4 6A618 Oil pump intermediate shaft 5 6020 Engine front cover gasket 6 6010 Cylinder block 7 6019 Engine front cover 8 6714 Oil bypass filter 9 6C315 Crankshaft position sensor 10 8501 Water pump 11 6312 Crankshaft pulley ...

Page 945: ... 9F797 Engine wire harness 2 9E926 Throttle body 3 9F670 Idle air control gasket 4 9F715 Idle air control valve 5 9E498 Emissions vacuum harness 6 9424 Intake manifold upper 7 9H486 Intake manifold gasket upper 8 12029 Ignition coil ...

Page 946: ...tomatic transmission 20 6375 Flywheel manual transmission 21 6A372 Engine rear plate manual transmission 22 6723 Oil pan rear seal 23 6675 Oil pan 24 7120 Pilot bushing 25 9278 Oil pressure sensor 26 9B339 Oil pressure sensor fitting 27 9A424 Intake manifold seal front 28 18663 Heater water outlet tube 29 8255 Thermostat housing to intake manifold gasket 30 8592 Water outlet connection 31 9875 Wat...

Page 947: ...stributor drive gear 2 6268 Timing chain 3 6A303 Engine balance shaft drive gear 4 6A304 Engine balance shaft driven gear 5 6C341 Balance shaft thrust plate 6 6A311 Engine dynamic balance shaft 7 W705934 Woodruff key 8 6261 Camshaft bearing ...

Page 948: ...d tube 23 6625 Oil pump inlet tube gasket 24 6334 Main bearing cap 25 6329 Main bearing cap 26 6303 Crankshaft 27 388907 Woodruff key 28 6333 Crankshaft main bearing upper 29 6284 Timing chain vibration damper 30 6263 Camshaft rear bearing 31 6262 Camshaft center bearing 32 6250 Camshaft 33 6265 Camshaft sprocket spacer 34 6269 Camshaft thrust plate 35 6256 Camshaft sprocket 36 6303 Crankshaft spr...

Page 949: ......

Page 950: ...STING Engine Refer to Section 303 00 for basic mechanical concerns or refer to the Powertrain Control Emissions Diagnosis PC ED manual for driveability concerns SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual ...

Page 951: ...n 303 12 3 Disconnect the vacuum hose and the idle air control IAC valve electrical connector 4 Disconnect the throttle position TP sensor electrical connector and the evaporative emissions EVAP return tube 5 Disconnect the accelerator and the speed control cables from the throttle body cam 6 Remove the bolts and position the accelerator cable bracket assembly aside SECTION 303 01A Engine 3 8L 200...

Page 952: ...back exhaust gas recirculation EGR system electrical and vacuum connections 8 Disconnect the EGR vacuum regulator solenoid electrical and vacuum connections 9 Disconnect the positive crankcase ventilation PCV tube 10 Disconnect the vacuum hoses ...

Page 953: ...interference capacitor electrical connector Spark plug wires 12 Disconnect the vacuum hose 13 NOTE For ease in installation record the location of the long bolts and the short bolts Remove the upper intake manifold 1 Remove the 12 bolts 2 Remove the upper intake manifold ...

Page 954: ...tallation 1 Install a new upper intake manifold gasket 2 NOTE Refer to the location note made during removal and make sure the bolts are installed in the correct locations Install the upper intake manifold Tighten the bolts in two stages in the sequence shown ...

Page 955: ...to 10 Nm 89 lb in Stage 2 Rotate an additional 90 degrees 1 4 turn 3 Connect the vacuum hose 4 Connect the following Ignition coil electrical connector Radio interference capacitor electrical connector Spark plug wires ...

Page 956: ...t the vacuum hoses 6 Connect the PCV tube 7 Connect the differential pressure feedback EGR system electrical and vacuum connections 8 Connect the EGR vacuum regulator solenoid electrical and vacuum connections ...

Page 957: ...ket and install the bolts 10 Connect the accelerator and speed control cables to the throttle body cam 11 Connect the EVAP return tube and the TP sensor electrical connector 12 Connect the vacuum hose and the IAC valve electrical connector ...

Page 958: ...13 Install the engine air cleaner outlet pipe For additional information refer to Section 303 12 14 Connect the battery ground cable For additional information refer to Section 414 01 ...

Page 959: ...Disconnect the fuel rail pressure FRP sensor electrical connector and vacuum hose 5 Disconnect the fuel supply tube spring lock coupling For additional information refer to Section 310 00 6 Disconnect and position the engine wire harness aside 7 Disconnect the intake manifold runner control IMRC electrical connector SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual Material Item Specificati...

Page 960: ...itional information refer to Section 303 03A 9 Disconnect the heater hose 10 Disconnect the exhaust gas recirculation EGR vacuum tube 11 Disconnect the EGR tube from the EGR valve 12 Disconnect the radiator upper hose and coolant bypass hose ...

Page 961: ... injectors as an assembly Remove the bolts and the fuel injection supply manifold 15 NOTE For ease in installation record the location of the short bolts and the long bolts Remove the lower intake manifold 1 Remove the eight short bolts 2 Remove the six long bolts 3 Remove the lower intake manifold ...

Page 962: ... Failure to follow this procedure can cause future oil leakage Install the lower intake manifold front and rear end seals 1 Apply a bead of silicone gasket and sealant to the intake manifold front and rear end seal mounting points as indicated 2 Install the lower intake manifold front and rear end seals Item Part Number Description 1 9439 Intake manifold gasket RH 2 9441 Intake manifold gasket LH ...

Page 963: ...cleaned with metal surface cleaner Allow to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure can cause future oil leakage Position the lower intake manifold 1 Apply a bead of silicone gasket and sealant to the lower intake manifold mounting at the points indicated 2 Position the lower intake manifold ...

Page 964: ...the correct location Tighten the bolts in two stages in the sequence shown Stage 1 Tighten the bolts to 5 Nm 44 lb in Stage 2 Tighten the bolts to 10 Nm 89 lb in 5 NOTE Install the fuel injection supply manifold and fuel injectors as an assembly Install the fuel injector supply manifold and bolts ...

Page 965: ...6 Connect the electrical connector 7 Connect the coolant hoses 8 Connect the EGR tube 9 Connect the EGR vacuum tube 10 Lubricate the O ring with water and install the heater hose ...

Page 966: ...2 Connect the IMRC electrical connector 13 Position and connect the engine wire harness Install the pin type retainers 14 Connect the fuel supply tube spring lock coupling For additional information refer to Section 310 00 15 Connect the FRP sensor electrical connector and the vacuum hose ...

Page 967: ...or additional information refer to Upper Intake Manifold in this section 17 CAUTION Correct cooling system bleeding is critical for correct engine cooling Fill and bleed the cooling system For additional information refer to Section 303 03A ...

Page 968: ...e ventilation PCV valve 6758 3 Remove the ignition coil and position aside 1 Disconnect the electrical connector 2 Disconnect the accelerator control cable retainer 3 Remove the bolts 4 Remove the LH valve cover 6A565 Inspect the gasket 6584 and install a new gasket if necessary SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual ...

Page 969: ...5 To install reverse the removal procedure ...

Page 970: ...n refer to Section 303 04A 2 Disconnect the crankcase vent hose 3 Remove the differential feedback exhaust gas recirculation EGR system vacuum hoses and the bracket bolts Position the bracket assembly aside 4 Disconnect the EGR tube 5 Remove the EGR tube SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual ...

Page 971: ...6 Position the spark plug wires aside 7 Remove the RH valve cover 8 To install reverse the removal procedure Install a new valve cover gasket as necessary ...

Page 972: ......

Page 973: ...information refer to Section 100 02 4 Remove the crankshaft pulley bolt SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual Special Tool s Remover Crankshaft Vibration Damper 303 009 T58P 6316 D Remover Crankshaft Vibration Damper 303 176 T82L 6316 B Installer Crankshaft Damper Crankshaft Front Oil Seal 303 175 T82L 6316 A Material Item Specification Silicone Gasket and Sealant F7AZ 19554 EA ...

Page 974: ...the crankshaft pulley 6B321 Installation 1 Apply a bead of silicone gasket and sealant to the keyway in the crankshaft damper and use the special tool to install the crankshaft pulley 2 Install the crankshaft bolt 3 Lower the vehicle ...

Page 975: ...4 Install the radiator coolant recovery reservoir 5 Install the drive belt For additional information refer to Section 303 05 ...

Page 976: ...e and discard the crankshaft front seal Installation SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual Special Tool s Installer Front Cover Oil Seal 303 335 T88T 6701 A Installer Crankshaft Front Oil Seal 303 474 T94P 6701 AH Remover Oil Seal 303 409 T92C 6700 CH Material Item Specification SAE 5W 20 Premium Synthetic Blend Motor Oil XO 5W20 QSP or equivalent WSS M2C153 H ...

Page 977: ...e crankshaft front seal with clean engine oil before assembly Using the special tool install the crankshaft front seal 2 Install the crankshaft pulley For additional information refer to Crankshaft Pulley in this section ...

Page 978: ...o Crankshaft Pulley in this section 4 Remove the water pump pulley 5 Remove the retainers and position the power steering pump aside 6 Disconnect the exhaust gas recirculation EGR tube SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual Material Item Specification Metal Surface Cleaner F4AZ 19A536 RA or equivalent WSE M5B392 A Silicone Gasket and Sealant F7AZ 19554 EA or equivalent WSE M4G323...

Page 979: ...e and the bypass hose 8 Remove the camshaft position CMP sensor 9 Remove the heater water outlet tube For additional information refer to Section 303 03A 10 Remove the camshaft synchronizer assembly 11 Disconnect the lower radiator hose ...

Page 980: ...12 Disconnect the crankshaft position sensor electrical connector 13 Remove the wiring harness pin type retainer 14 Remove the oil filter 15 Remove the retainers and the water pump ...

Page 981: ...hese directions will result in engine damage CAUTION Do not use a surface conditioning pad or any other type of fibrous abrasive disc to clean the gasket surfaces Failure to follow these directions will result in engine damage Clean and inspect the engine block and front cover as follows Pack the exposed portion of the oil pan with clean shop towels Plug the oil and coolant passages Clean the gask...

Page 982: ...t of silicone gasket and sealant as shown 3 NOTE If the engine front cover is not secured within four minutes the sealant must be removed and the sealing area cleaned with metal surface cleaner Allow to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure can cause future oil leakage Install the engine front cover gasket and apply silicone gask...

Page 983: ...6 NOTE The number 12 bolt is not part of the tightening sequence Tighten the fasteners to 26 Nm 19 lb ft in the sequence shown 7 Install a new oil filter 8 Install the wiring harness pin type retainer ...

Page 984: ... radiator hose 11 Install the camshaft synchronizer assembly For additional information refer to Section 303 14 12 Install the heater water outlet tube For additional information refer to Section 303 13 13 Install the camshaft position CMP sensor and connect the electrical connector ...

Page 985: ...se and the upper radiator hose 15 Connect the EGR tube 16 Install the power steering pump 17 Install the water pump pulley 18 Install the crankshaft pulley For additional information refer to Crankshaft Pulley in this section ...

Page 986: ...engine oil and fill with clean engine oil 20 Fill the engine cooling system For additional information refer to Section 303 03A 21 Connect the battery ground cable For additional information refer to Section 414 01 ...

Page 987: ...ve Cover LH and Valve Cover RH in this section 2 Remove the rocker arm assembly Remove the bolt Installation 1 Install the rocker arms tighten the bolts in two stages Stage 1 tighten to 5 Nm 44 lb in Stage 2 tighten to 35 Nm 26 lb ft 2 Install the valve covers For additional information refer to Valve Cover LH and Valve Cover RH in this section SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Man...

Page 988: ......

Page 989: ... the rocker arms 6564 For additional information refer to Rocker Arm in this section 2 Remove the push rods 6565 3 Inspect the components For additional information refer to Section 303 00 Installation 1 To install reverse the removal procedure SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual ...

Page 990: ......

Page 991: ... a minimum of 965 kPa 140 psi of compressed air into the cylinder 4 CAUTION If the components are to be reinstalled they must be installed in the same position Mark the components for location NOTE If a valve drops into the cylinder remove the cylinder head For additional information refer to Cylinder Head LH or Cylinder Head RH in this section Remove the rocker arms 1 Remove the bolts 2 Remove th...

Page 992: ... spring assembly 1 Remove the valve spring retainer key 2 Remove the valve spring retainer 3 Remove the valve spring 4 Remove and discard the valve stem seal and spring seat assembly 7 Inspect the components For additional information refer to Section 303 00 Installation ...

Page 993: ...1 NOTE Lubricate the parts with clean engine oil To install reverse the removal procedure Tighten the rocker arm bolts in two stages Stage 1 Tighten to 5 Nm 44 lb in Stage 2 Tighten to 35 Nm 26 lb ft ...

Page 994: ...ds For additional information refer to Push Rod 3 Remove the eight valve tappets 1 Remove the bolts 2 Remove the tappet guide plate and retainer 3 Remove the valve tappets Installation 1 NOTE Lubricate the valve tappet with clean engine oil before installing To install reverse the removal procedure SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual Material Item Specification SAE 5W 20 Premi...

Page 995: ......

Page 996: ...ain in this section 3 Position the wire harness aside 4 Remove the radiator fan and shroud assembly 5 Remove the engine balance shaft drive gear from the camshaft 1 Remove the camshaft key 2 Remove the engine balance shaft drive gear SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual Material Item Specification SAE 5W 20 Premium Synthetic Blend Motor Oil XO 5W20 QSP or equivalent WSS M2C153 ...

Page 997: ...1 Remove the bolts 2 Remove the camshaft thrust plate 3 Remove the spacer 4 Remove the camshaft Installation 1 NOTE Lubricate the camshaft with clean engine oil prior to installation To install reverse the removal procedure ...

Page 998: ......

Page 999: ...s section 2 Disconnect and position the wire harness aside 3 Remove the radiator fan and shroud assembly 8146 4 Remove the engine dynamic balance shaft 6A311 Remove the bolts Remove the balance shaft driver gear thrust plate and engine dynamic balance shaft as an assembly Installation SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual ...

Page 1000: ...en gear so that the timing mark lines up with the timing mark on the engine balance shaft drive gear 6A303 2 NOTE If correctly aligned the engine dynamic balance shaft keyway will be at 12 o clock and the camshaft keyway will be at 6 o clock on the camshaft Install the bolts 3 Install the radiator fan and shroud assembly 4 Connect the connector and install the pin type retainer ...

Page 1001: ...5 Install the timing chain For additional information refer to Timing Chain in this section ...

Page 1002: ... 1 Remove the bolt 2 Remove the camshaft position sensor drive gear 3 Rotate the crankshaft 6303 until the timing marks and keyways align 4 Compress and install a retaining pin to hold the timing chain tensioner 6L266 5 Remove the camshaft sprocket 6256 the crankshaft sprocket 6306 and the timing chain belt 6268 as an assembly SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual ...

Page 1003: ...move the timing chain tensioner Installation 1 Install the timing chain tensioner 1 Position the timing chain tensioner 2 Install the bolts 2 Rotate the crankshaft so the number one piston 6108 is at top dead center TDC and the key is at the 12 o clock position ...

Page 1004: ...r pad retracting mechanism 2 Insert a retaining pin 4 Turn the camshaft sprocket so that the timing mark is on the bottom of the balance shaft 6250 5 Install the timing chain the camshaft sprocket and the crankshaft sprocket 6 Make sure that the timing marks and the keyways are aligned ...

Page 1005: ...7 Install the camshaft position sensor drive gear 8 Remove the retaining pin 9 Install the engine front cover For additional information refer to Engine Front Cover in this section ...

Page 1006: ......

Page 1007: ...nformation refer to Section 100 02 2 Remove the LH exhaust manifold flange nuts 3 Remove the RH exhaust manifold flange nuts 4 Lower the vehicle 5 NOTE Discard the exhaust manifold gasket Remove the LH exhaust manifold 9431 Remove the nuts SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual ...

Page 1008: ...Installation 1 NOTE Install a new gasket NOTE Tighten the nuts in the sequence shown To install reverse the removal procedure ...

Page 1009: ......

Page 1010: ...eaner outlet pipe For additional information refer to Section 303 12 3 Disconnect the differential pressure feedback exhaust gas recirculation EGR system electrical and vacuum connections 4 Disconnect the EGR tube 5 Remove the EGR tube 6 Raise and support the vehicle For additional information refer to Section 100 02 SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual ...

Page 1011: ...haust manifold flange nuts 9 Lower the vehicle 10 NOTE Discard the exhaust manifold gasket Remove the RH exhaust manifold retaining nuts and the RH exhaust manifold 11 To install reverse the removal procedure Tighten the exhaust manifold nuts in the sequence shown ...

Page 1012: ......

Page 1013: ...ional information refer to Lower Intake Manifold in this section 5 Remove the push rods For additional information refer to Push Rod in this section 6 Remove the drive belt For additional information refer to Section 303 05 7 Using the special tool remove the power steering pump pulley SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual Special Tool s Remover Power Steering Pump Pulley 211 01...

Page 1014: ... the power steering pump bracket 9 Remove the generator bracket 10 Remove the three exhaust manifold studs 11 NOTE Discard the cylinder head gasket NOTE Record the location of the long bolts and the short bolts ...

Page 1015: ... flatness For additional information refer to Section 303 00 2 Install a new head gasket on the cylinder block with the small hole to the front of the engine 3 Position the cylinder head 4 CAUTION Always use new bolts NOTE Lubricate the bolts with clean engine oil Install new bolts Refer to the location note made during removal and make sure the bolts are installed the correct location 1 Install t...

Page 1016: ...sened and final tightened prior to working on the next bolt in the sequence NOTE The short bolts are numbered 2 4 6 and 8 and the long bolts numbered 1 3 5 and 7 Loosen then tighten the bolts in two stages in the sequence shown Stage 1 Tighten short bolts to 25 Nm 18 lb ft then tighten an additional 180 degrees Stage 1 Tighten long bolts to 45 Nm 33 lb ft then tighten an additional 180 degrees 7 I...

Page 1017: ... the lower intake manifold For additional information refer to Lower Intake Manifold in this section 14 Install the LH exhaust manifold For additional information refer to Exhaust Manifold LH in this section 15 Connect the battery ground cable For additional information refer to Section 414 01 16 CAUTION Correct cooling system bleeding is critical for correct engine cooling Fill and bleed the engi...

Page 1018: ......

Page 1019: ...formation refer to Lower Intake Manifold in this section 5 Remove the push rods For additional information refer to Push Rod in this section 6 Remove the drive belt For additional information refer to Section 303 05 7 Disconnect the A C manifold and tube assembly For additional information refer to Section 412 03 8 Disconnect the A C compressor clutch electrical connector 9 Remove the A C compress...

Page 1020: ...er head bolts Installation NOTE Do not use a fiber disc to clean the surfaces Fibers from the disc can get into the oil pan and oil and clog the oil bypass valve 1 Clean and inspect the cylinder head for flatness For additional information refer to Section 303 00 2 Install a new head gasket on the cylinder block with the small hole to the front of the engine and position the cylinder head ...

Page 1021: ...s 2 Install the new short bolts 4 Tighten the bolts in three stages in the sequence shown Stage 1 Tighten to 20 Nm 15 lb ft Stage 2 Tighten to 40 Nm 30 lb ft Stage 3 Tighten to 50 Nm 37 lb ft 5 CAUTION Do not loosen all of the bolts at one time Each bolt must be loosened and final tightened prior to working on the next bolt in the sequence NOTE The short bolts are numbered 2 4 6 and 8 and the long...

Page 1022: ... short bolts to 25 Nm 18 lb ft then tighten an additional 180 degrees Tighten long bolts to 45 Nm 33 lb ft then tighten an additional 180 degrees 6 Install the three studs 7 Install the bracket and bolts 8 Connect the A C compressor clutch electrical connector ...

Page 1023: ...al information refer to Lower Intake Manifold in this section 13 Install the RH exhaust manifold For additional information refer to Exhaust Manifold RH in this section 14 Connect the battery ground cable For additional information refer to Section 414 01 15 CAUTION Correct cooling system bleeding is critical for correct engine cooling Fill and bleed the engine cooling system For additional inform...

Page 1024: ...nstallation 1 Remove the oil level indicator tube 6754 Remove the bolt Remove the oil level indicator tube Remove and discard the oil level indicator tube O ring 2 To install reverse the removal procedure SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual ...

Page 1025: ......

Page 1026: ... 1 Disconnect the hose SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual Special Tool s 3 Bar Engine Support Kit 303 F072 Lifting Bracket Set Engine 303 D095 D94L 6001 A or equivalent Material Item Specification SAE 5W 20 Premium Synthetic Blend Motor Oil XO 5W20 QSP or equivalent WSS M2C153 H Metal Surface Cleaner F4AZ 19A536 RA or equivalent WSE M5B392 A Silicone Gasket and Sealant F7AZ 1...

Page 1027: ...he bolts 3 Remove the coolant recovery reservoir 5 Install the special tool 6 Install the special tool 7 Install the special tool 8 Raise and support the vehicle For additional information refer to Section 100 02 ...

Page 1028: ...ount nut 10 Remove the RH engine mount nut 11 Lower the vehicle 12 Raise the engine 13 Raise and support the vehicle For additional information refer to Section 100 02 14 Remove the oil pan drain plug and drain the engine oil ...

Page 1029: ...otor For additional information refer to Section 303 06 16 Position the wiring harness bracket aside 17 Remove the transmission lower bolts 18 Remove the oil pan bolts 19 Position a safety stand under the subframe crossmember ...

Page 1030: ...20 Remove the four subframe lower bolts 21 Remove the two subframe upper bolts 22 NOTE Do not completely remove these bolts Loosen the two bolts 23 Lower the front subframe ...

Page 1031: ...ess or four minutes whichever is longer Failure to follow this procedure can cause future oil leakage Clean and apply sealant to the oil pan sealing areas shown and install the oil pan rear seal 1 Apply silicone gasket and sealant to the rear main bearing cap 2 Install the oil pan rear seal 3 Clean the oil pan mating surfaces with metal surface cleaner an apply silicone gasket and sealant to the o...

Page 1032: ...2 Position the oil pan and start the bolts 3 Tighten the bolts in two stages in the sequence shown Stage 1 Tighten to 5 Nm 44 lb in Stage 2 Tighten to 10 Nm 89 lb in ...

Page 1033: ...4 Install the transmission lower bolts 5 Install the oil pan drain plug 6 Raise the front subframe into position ...

Page 1034: ...7 Tighten the two bolts 8 Install the two bolts 9 Install the four subframe lower bolts 10 Remove the safety stand ...

Page 1035: ...all the starter motor For additional information refer to Section 303 06 13 Lower the vehicle 14 Lower the engine 15 Raise and support the vehicle For additional information refer to Section 100 02 16 Install the RH engine mount nut ...

Page 1036: ...17 Install the LH engine mount nut 18 Lower the vehicle 19 Remove the special tools 20 Install the coolant recovery reservoir 21 Install the radiator sight shield ...

Page 1037: ... Connect the battery ground cable For additional information refer to Section 414 01 24 Fill the engine with clean engine oil 25 CAUTION Correct coolant bleeding is critical for correct engine cooling Fill and bleed the engine cooling system For additional information refer to Section 303 03A ...

Page 1038: ...e oil pump screen cover and tube 6622 For additional information refer to Oil Pump Screen and Pickup Tube in this section 2 Remove the oil pan baffle 6687 Remove the nuts 3 To install reverse the removal procedure SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual ...

Page 1039: ...el Removal and Installation 1 Remove the clutch For additional information refer to Section 308 01 2 Remove the flywheel bolts 3 To install reverse the removal procedure SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual ...

Page 1040: ......

Page 1041: ...tion refer to Oil Pan in this section 2 Remove the oil pump screen cover and tube 6622 and discard the gasket 1 Remove the nut 2 Remove the two bolts 3 Remove the oil pump screen cover and tube 4 Remove and discard the gasket 3 To install reverse the removal procedure SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual ...

Page 1042: ......

Page 1043: ...move the transmission For additional information refer to Section 307 01 2 Remove the six bolts retaining the flexplate to crankshaft and remove the flexplate 3 To install reverse the removal procedure SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual ...

Page 1044: ... 100 A Remover Crankshaft Rear Seal 303 519 T95P 6701 EH Replacer Rear Crankshaft Seal 303 516 T95P 6701 BH Spacer Rear Crank Seal Replacer 303 561 T96T 6701 B Adapter Crankshaft Rear Seal Use only the adapter retaining bolts 303 518 T95P 6701 DH Adapter Crankshaft Rear Seal Use only the adapter and the center jack screw 303 S560 T96T 6701 A Material Item Specification SAE 5W 20 Premium Synthetic ...

Page 1045: ...bricate the crankshaft rear seal lips with clean engine oil prior to installation Assemble the special tools and the crankshaft rear seal 3 Install the special tools on the rear of the crankshaft 4 Install the crankshaft rear seal Tighten the center jack screw 303 S560 until the spacer 303 561 contacts the engine block ...

Page 1046: ...5 Install the flywheel or the flexplate For additional information refer to Flexplate in this section ...

Page 1047: ...659 For additional information refer to Section 303 12 3 Remove the radiator sight shield 8C291 4 Remove the coolant recovery reservoir 8A080 1 Disconnect the hose 2 Remove the bolts 3 Remove the coolant recovery reservoir SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual Special Tool s 3 Bar Engine Support Kit 303 F072 Engine Lift Bracket Set 303 D095 D94L 6001 A or equivalent ...

Page 1048: ...5 Install the special tool 6 Install the special tool 7 Install the special tool 8 Raise the vehicle on a hoist For additional information refer to Section 100 02 9 Remove the LH engine mount nut ...

Page 1049: ...10 Remove the RH engine mount nut 11 Lower the vehicle 12 Raise the engine 13 Raise the vehicle on a hoist 14 Position the bracket aside Remove the nut ...

Page 1050: ...15 Disconnect the engine ground strap Remove the nut 16 Remove the LH engine insulator 6038 Remove the bolts 17 Remove the RH engine insulator Remove the bolts Remove the nuts ...

Page 1051: ...Installation 1 Install the RH engine insulator Install the nuts Install the bolts 2 Install the LH engine insulator 3 Connect the engine ground strap 4 Install the bracket ...

Page 1052: ...5 Lower the vehicle 6 Lower the engine 7 Raise the vehicle 8 Install the RH engine mount nut 9 Install the LH engine mount nut ...

Page 1053: ... Install the coolant recovery reservoir 13 Install the radiator sight shield 14 Install the air cleaner outlet tube For additional information refer to Section 303 12 15 Connect the battery ground cable For additional information refer to Section 414 01 ...

Page 1054: ......

Page 1055: ...ction 303 03A 2 Recover the A C refrigerant For additional information refer to Section 412 00 3 Disconnect the battery negative cable 14301 For additional information refer to Section 414 01 4 Relieve the fuel pressure For additional information refer to Section 310 00 5 Disconnect the hood ground strap SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual Special Tool s Lifting Bracket Set En...

Page 1056: ...e the hood 16612 7 Disconnect the vacuum hose 8 Disconnect the generator 10346 1 Disconnect the connectors 2 Remove the nut 3 Remove the battery positive cable 9 NOTE Place a suitable container under the pump ...

Page 1057: ...g pump 3A674 10 Disconnect the lower radiator hose 8286 11 Disconnect the upper radiator hose 8620 12 Remove the radiator coolant recovery reservoir 8A080 13 Disconnect the accelerator cable and if equipped the speed control cable ...

Page 1058: ...sembly For additional information refer to Section 303 12 16 Disconnect the A C manifold and tube 19D734 For additional information refer to Section 412 03 17 Disconnect the A C compressor electrical connector 18 Disconnect the fuel supply line 9J337 For additional information refer to Section 310 00 19 Disconnect the heater hoses 12270 ...

Page 1059: ...ct the following connectors 42 pin electrical connector 16 pin electrical connector 8 pin electrical connector A C pressure switch 21 Position the wire harness aside 22 Disconnect the connector and the vacuum tube ...

Page 1060: ...oist For additional information refer to Section 100 02 25 Remove the starter motor 11002 For additional information refer to Section 303 06 26 Remove the dual converter Y pipe 5F250 For additional information refer to Section 309 00 27 Remove the bracket 28 Remove the bracket Remove the nut ...

Page 1061: ...ne ground strap Remove the nut 30 Remove the bracket Vehicles equipped with manual transmission 31 Remove the transmission For additional information refer to Section 308 03A 32 Drain the engine oil Remove the oil drain plug ...

Page 1062: ... equipped with automatic transmission 33 Remove the access cover 34 NOTE Discard the torque converter nuts Disconnect the torque converter 7902 Remove the four nuts 35 Remove the oil pan to transmission bolts ...

Page 1063: ...36 Remove the upper bell housing bolts 37 Remove the transmission oil filler tube 7A228 All vehicles 38 Remove the RH engine mount nut 39 Remove the LH engine mount nut ...

Page 1064: ...le 41 Support the transmission 42 Install the special tool 43 Install the special tools 44 Using the special tool remove the engine 45 If necessary remove the flywheel 6375 and the separator plate 6A372 Remove the bolts ...

Page 1065: ...46 Mount the engine on a suitable engine stand ...

Page 1066: ...nual Special Tool s Service Set Camshaft 303 017 T65L 6250 A Remover Crankshaft Vibration Damper 303 009 T58P 6316 D Lifting Bracket Set Engine 303 D095 D94L 6001 A or equivalent Remover Power Steering Pump Pulley 211 016 T69L 10300 B Remover Oil Seal 303 409 T92C 6700 CH Remover Crankshaft Vibration Damper 303 176 T82L 6316 B ...

Page 1067: ...2 Remove the bolts and the RH engine support insulator 3 Remove the special tool 4 Remove the special tool 5 Remove the bolt and the oil level indicator and tube Discard the O ring ...

Page 1068: ... Remove the bolts and the LH exhaust manifold Discard the gasket 7 Disconnect the exhaust gas recirculation EGR tube 8 Remove the EGR tube 9 Remove the nuts and the RH exhaust manifold Discard the gasket ...

Page 1069: ...AC valve and throttle position TP sensor electrical connectors 11 Position the RH spark plug wires aside 12 Position the LH spark plug wires aside 13 Disconnect the ignition coil and the radio interference capacitor electrical connectors ...

Page 1070: ...ase ventilation PCV tube 15 Disconnect the vacuum hoses 16 Disconnect the differential pressure feedback EGR system electrical and vacuum connections 17 Disconnect the EGR vacuum regulator solenoid electrical and vacuum connections ...

Page 1071: ...e manifold and the upper intake manifold gasket 19 Remove the fuel injection supply manifold and the fuel injectors For additional information refer to Section 303 04A 20 Disconnect the cylinder head temperature CHT sensor 21 Disconnect the camshaft position CMP sensor electrical connector ...

Page 1072: ... the engine oil pressure sender electrical connector 23 Remove the pin type retainer 24 Disconnect the crankshaft position CKP sensor electrical connector 25 Remove the engine wiring harness 26 Remove the stud bolt ...

Page 1073: ...ter water outlet tube 28 NOTE Record the location of the long bolts and the short bolts Remove the lower intake manifold and the intake manifold gasket 29 Remove the accessory drive belt 30 Remove the water pump pulley ...

Page 1074: ...31 Remove the A C compressor bracket 32 Using the special tool remove the power steering pump pulley 33 Remove the power steering pump bracket 34 Remove the bolts and the generator mounting bracket ...

Page 1075: ...35 Remove the crankshaft pulley bolt 36 Using the special tool remove the crankshaft pulley 37 Remove the RH and the LH valve covers 38 Inspect the valve cover gaskets Install new gaskets if necessary ...

Page 1076: ...l pan 40 CAUTION If the components are to be reinstalled they must be installed into the same position Mark the components for location Remove the LH rocker arms 1 Remove the bolts 2 Remove the rocker arms 41 Remove the LH push rods ...

Page 1077: ...ation of the long bolts and the short bolts Remove and discard the LH cylinder head bolts 43 Remove the LH cylinder head and gasket Discard the gasket 44 Remove the RH rocker arms 1 Remove the bolts 2 Remove the rocker arms ...

Page 1078: ...45 Remove the RH push rods 46 NOTE Record the location of the long bolts and the short bolts Remove and discard the RH cylinder head bolts ...

Page 1079: ... 48 Remove the camshaft synchronizer For additional information refer to Section 303 14 49 Remove the bolts and the crankshaft position sensor 50 Using the special tool remove the crankshaft front seal 51 Remove the bolts and the front cover assembly and gasket ...

Page 1080: ...ft position sensor drive gear 53 Compress and install a retaining pin to hold the timing chain tensioner 54 Remove the camshaft sprocket the crankshaft sprocket and the timing chain as an assembly 55 Remove the timing chain tensioner 1 Remove the bolts 2 Remove the timing chain tensioner ...

Page 1081: ...driven gear thrust plate and engine dynamic balance shaft as an assembly 57 Remove the valve tappets 1 Remove the bolts 2 Remove the tappet guide plates and retainers 3 Remove the valve tappets 58 Remove the engine balance shaft drive gear 1 Remove the camshaft keyway 2 Remove the gear ...

Page 1082: ... 2 Remove the camshaft thrust plate 3 Remove the spacer 4 Remove the camshaft 60 Remove the bearing covers 1 Remove the engine dynamic balance shaft bearing cover 2 Remove the camshaft bearing cover 61 Remove the oil pump screen cover and tube ...

Page 1083: ...ssary remove the ridge or carbon deposits from each cylinder using a cylinder ridge reamer and following the manufacturer s instructions Remove the pistons 1 Make sure the piston being removed is at the bottom of the cylinder bore 2 Remove the bolts 3 Remove the connecting rod cap and the lower connecting rod bearing 4 CAUTION Be careful to avoid damage to the cylinder wall when removing the pisto...

Page 1084: ...g main bearing caps and the crankshaft lower main bearings 67 CAUTION The crankshaft journals must be protected from damage when the crankshaft is removed Remove the crankshaft and the crankshaft rear seal 68 NOTE For ease in assembly record the location of the crankshaft upper thrust bearing Remove the crankshaft upper main bearings and the crankshaft upper thrust bearing 69 Using the camshaft be...

Page 1085: ...aft bearings 71 If equipped remove the engine block heater For additional information refer to Section 303 03A 72 NOTE For cleaning purposes the plugs should be removed If necessary remove the following 1 the cylinder block dowels 2 the oil gallery plugs 3 the water jacket plugs ...

Page 1086: ......

Page 1087: ...ecessary 2 Using the special tool compress the valve springs 6513 3 Remove the following 1 The valve spring retainer key 6518 2 The valve spring retainers 6514 3 The valve springs 6513 4 The valve stem seals and seats 6A517 SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual Special Tool s Compressor Valve Spring 303 163 T81P 6513 A Material Item Specification SAE 5W 20 Premium Synthetic Blen...

Page 1088: ...4 Inspect the components For additional information refer to Section 303 00 5 CAUTION Lubricate the parts with clean engine oil before installing To assemble reverse the disassembly procedure ...

Page 1089: ...nnecting rod from the piston 3 Clean and inspect the connecting rod and piston For additional information refer to Section 303 00 Assembly SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual Special Tool s Piston Pin Tool or equivalent 303 D034 D81L 6135 A Material Item Specification SAE 5W 20 Premium Synthetic Blend Motor Oil XO 5W20 QSP or equivalent WSS M2C153 H ...

Page 1090: ... bore with clean engine oil 2 NOTE The connecting rod can be installed in either direction Position the piston pin in the bore aligned with the connecting rod bore 3 Using the special tool press the piston pin into the piston and rod assembly ...

Page 1091: ......

Page 1092: ...3 176 T82L 6316 B Installer Crankshaft Front Seal 303 474 T94P 6701 AH Replacer Steering Pump Pulley 211 009 T65P 3A733 C Engine Lift Bracket Set 303 D095 D94L 6001 A Replacer Rear Crankshaft Seal 303 516 T95P 6701 BH Spacer Rear Crank Seal Replacer 303 561 T96T 6701 B Adapter Crankshaft Rear Seal Use only the adapter retaining bolts 303 518 T95P 6701 DH ...

Page 1093: ...formation refer to Section 303 03A 3 Using the camshaft bearing service set install the engine dynamic balance shaft bearings Adapter Crankshaft Rear Seal Use only the adapter and the center jack screw 303 S560 T96T 6701 A Spreader Bar 303 D089 D93P 6001 A3 Material Item Specification Metal Surface Cleaner F4AZ 19A536 RA or equivalent WSE M5B392 A Silicone Gasket and Sealant F7AZ 19554 EA or equiv...

Page 1094: ...tall the camshaft bearings 5 Install the following 1 the engine dynamic balance shaft bearing cover 2 the camshaft bearing cover 6 CAUTION Do not damage the camshaft lobes when installing the camshaft Install the camshaft and the camshaft spacer ...

Page 1095: ... the timing mark aligns up with the timing mark on the engine balance shaft drive gear 9 NOTE If correctly aligned the engine dynamic balance shaft keyway will be at 12 o clock and the camshaft keyway will be at 6 o clock on the camshaft Install the bolts 10 CAUTION Make sure the components are installed in the correct location NOTE Lubricate the crankshaft main bearings prior to installation Inst...

Page 1096: ...TE If the rear main bearing cap is not secured within four minutes the sealant must be removed and the sealing area cleaned with metal surface cleaner Allow to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure can cause future oil leakage Clean the rear main bearing cap sealing area with metal surface cleaner Apply silicone gasket and sealan...

Page 1097: ...aps Tighten the bolts in two stages Stage 1 Tighten to 50 Nm 37 lb ft Stage 2 Rotate an additional 120 degrees 14 Compress the piston rings 15 CAUTION Inspect the piston clearance For additional information refer to Section 303 00 ...

Page 1098: ...ditional information refer to Section 303 00 CAUTION The connecting rod cap will fit only one way Position the connecting lower rod bearing and the connecting rod cap on the connecting rod and the crankshaft journal 17 Install the rod caps Tighten the bolts in three stages Stage 1 Tighten to 25 Nm 18 lb ft Stage 2 Tighten to 45 Nm 33 lb ft Stage 3 Tighten an additional 105 degrees 18 Install the r...

Page 1099: ...sket install the oil pump screen cover and tube 21 Install the timing chain tensioner 1 Position the timing chain tensioner 2 Install the bolts 22 Retract the tensioner pad retracting mechanism 1 Compress the tensioner pad retracting mechanism 2 Insert a retaining pin ...

Page 1100: ...position 24 Turn the camshaft sprocket so that the keyway is on the bottom of the camshaft 25 Install the timing chain the camshaft sprocket and the crankshaft sprocket as an assembly 26 Make sure the timing marks and the keyways are aligned 27 Install the camshaft position sensor drive gear and retaining bolt ...

Page 1101: ...location 29 NOTE Install the new cylinder head gaskets with the small hole to the front of the engine Using new gaskets install the RH and the LH cylinder heads 30 CAUTION Always use new bolts NOTE Lubricate the bolts with clean engine oil prior to installation Position the new bolts 1 Position the new long bolts 2 Position the new short bolts ...

Page 1102: ...d and tightened prior to working on the next bolt in the sequence Tighten the bolts in four stages in the sequence shown short bolts numbered 2 4 6 and 8 Stage 1 Tighten to 25 Nm 18 lb ft Stage 2 Tighten an additional 180 degrees Long bolts numbered 1 3 5 and 7 Stage 3 Tighten to 45 Nm 33 lb ft Stage 4 Tighten an additional 180 degrees 33 NOTE Lubricate the valve tappets with clean engine oil prio...

Page 1103: ...section 36 NOTE Use pipe sealant with Teflon on studs No 4 and 6 and bolt No 12 Using a new gasket install the engine front cover Tighten the nuts and the bolts in the sequence shown Install a 135 5 mm 5 42 in stud at location No 5 and tighten to 7 Nm 62 lb in Install a 137 mm 5 48 in stud at locations No 4 6 7 and 10 and tighten to 7 Nm 62 lb in Using a new gasket install the water pump Tighten b...

Page 1104: ...efore assembly Using the special tool install the front crankshaft seal 38 Install the crankshaft position sensor 39 Apply a bead of silicone gasket and sealant to the keyway in the crankshaft damper Using the special tool position and install the crankshaft damper ...

Page 1105: ...d with metal surface cleaner Allow to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure can cause future oil leakage Clean and apply the sealant to the oil pan sealing areas shown and install the oil pan rear seal 1 Apply silicone gasket and sealant to the rear main bearing cap 2 Install the oil pan rear seal 3 Clean the oil pan mating surfa...

Page 1106: ...44 Tighten the oil pan bolts in the sequence shown 45 Install the RH valve cover ...

Page 1107: ...46 Install the LH valve cover 47 Install the generator mounting bracket 48 Install the power steering pump bracket 49 Using the special tool install the power steering pump pulley ...

Page 1108: ...s 51 Install the accessory drive belt 52 Refer to the illustration for intake manifold sealing components Item Part Number Description 1 9439 Intake manifold gasket RH 2 9441 Intake manifold gasket LH 3 9A424 Intake manifold rear end seal part of 9439 ...

Page 1109: ...nting points as indicated 2 Install the lower intake manifold front and rear end seals 54 Install the intake manifold gaskets 55 NOTE If the lower intake manifold is not secured within four minutes the sealant must be removed and the sealing area cleaned with metal surface cleaner Allow to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure ca...

Page 1110: ...old bolts Install the six long bolts Install the eight short bolts 57 Tighten the bolts in two stages in the sequence shown 1 Stage 1 Tighten to 5 Nm 44 lb in 2 Stage 2 Tighten to 10 Nm 89 lb in 58 Install the heater water outlet tube ...

Page 1111: ...59 Install the stud bolt 60 Position the engine wire harness 61 Connect the crankshaft position sensor electrical connector 62 Install the pin type retainer ...

Page 1112: ...mshaft position CMP sensor electrical connector 65 Connect the cylinder head temperature CHT sensor 66 Install the fuel injectors and the fuel injection supply manifold as an assembly For additional information refer to Section 303 04A 67 Install a new upper intake manifold gasket ...

Page 1113: ...d in the correct location Install the upper intake manifold Tighten the bolts in two stages in the sequence shown Stage 1 Tighten to 10 Nm 89 lb in Stage 2 Rotate an additional 90 degrees 69 Connect the exhaust gas recirculation EGR vacuum regulator solenoid electrical and vacuum connections ...

Page 1114: ...em electrical and vacuum connections 71 Connect the vacuum hoses 72 Install the positive crankcase ventilation PCV tube 73 Connect the ignition coil and the radio interference capacitor electrical connectors 74 Position and connect the LH spark plug wires ...

Page 1115: ...ires 76 Connect the idle air control IAC valve and the throttle position TP sensor electrical connectors 77 Install the RH exhaust manifold Install a new exhaust manifold gasket Install the exhaust manifold Tighten the nuts in the sequence shown ...

Page 1116: ...culation EGR tube 79 Connect the EGR valve nut 80 Using a new gasket install the LH exhaust manifold Tighten the nuts in the sequence shown 81 NOTE Install a new O ring seal Install the oil level indicator and tube and retaining bolt ...

Page 1117: ...82 Install the special tool 83 Install the special tool 84 Install the RH engine support insulator 85 Install the LH engine support insulator 86 Remove the engine from the stand ...

Page 1118: ... oil prior to installation Assemble the special tools and the crankshaft rear seal 88 Install the special tools on the rear of the crankshaft 89 Install the crankshaft rear seal Tighten the center jack screw 303 S560 until the spacer 303 561 contacts the engine block ...

Page 1119: ......

Page 1120: ...ols position the engine in the vehicle SECTION 303 01A Engine 3 8L 2003 Mustang Workshop Manual Special Tool s Heavy Duty Floor Crane 014 00071 or equivalent Spreader Bar 303 D089 D93P 6001 A3 or equivalent Material Item Specification SAE 5W 20 Premium Synthetic Blend Motor Oil XO 5W20 QSP or equivalent WSS M2C153 H ...

Page 1121: ...nal information refer to Section 100 02 5 Install the LH engine mount nut 6 Install the RH engine mount nut Vehicles equipped with manual transmission 7 Install the transmission For additional information refer to Section 308 03A 8 Install the transmission oil filler tube ...

Page 1122: ...Vehicles equipped with automatic transmission 9 Install the five bellhousing upper bolts 10 Install the bolts 11 Install the four torque converter nuts All vehicles ...

Page 1123: ...12 Install the access cover 13 Install the oil pan drain plug 14 Install the bracket 15 Connect the engine ground strap 16 Install the bracket ...

Page 1124: ... Y pipe For additional information refer to Section 309 00 19 Install the starter motor For additional information refer to Section 303 06 20 Lower the vehicle 21 Connect the evaporative emissions EVAP return tube 22 Connect the connector and vacuum tube ...

Page 1125: ...23 Position the wiring harness 24 Connect the following connectors 42 pin electrical connector 16 pin electrical connector 8 pin electrical connector A C pressure switch 25 Connect the heater hoses ...

Page 1126: ...0 27 Connect the A C compressor electrical connector 28 Connect the A C manifold and tube For additional information refer to Section 412 03 29 Install the air cleaner outlet tube For additional information refer to Section 303 12 30 Install the accelerator cable bracket 31 Connect the accelerator cable ...

Page 1127: ...tall the radiator coolant recovery reservoir 33 Connect the upper radiator hose 34 Connect the lower radiator hose 35 Connect the power steering pump Connect the power steering return hose Position the clamp ...

Page 1128: ...Connect the power steering pressure tube 36 Connect the generator electrical connections 37 Connect the vacuum hose 38 Install the hood 39 Connect the hood ground strap ...

Page 1129: ...e engine with clean engine oil 42 Fill the engine cooling system For additional information refer to Section 303 03A 43 Recharge the A C refrigerant system For additional information refer to Section 412 00 44 Fill and bleed the power steering system For additional information refer to Section 211 00 ...

Page 1130: ...Valve Train Combustion chamber volume 43 9 1 5 cm 3 Valve arrangement front to rear LH b E I E I E I E I Valve arrangement front to rear RH b I E I E I E I E Valve guide bore diameter 7 015 7 044 mm 0 2762 0 2773 in Valve stem diameter 6 975 6 995 mm 0 2754 0 2746 in Valve stem to guide clearance intake 0 020 0 069 mm 0 00078 0 00272 in Valve stem to guide clearance exhaust 0 046 0 095 mm 0 0018 0...

Page 1131: ...in Camshaft journal to bearing clearance service limit 0 100 mm 0 003937 in max Runout Front and rear journals 0 03 mm 0 001 in Runout four inner journals 0 09 mm 0 003 in End play 0 027 0 190 mm 0 001 0 007 in End play service limit 0 190 mm 0 007480 in Cylinder Block Cylinder bore diameter 31 mm 1 24 in from top of block red 90 200 90 210 blue 90 210 90 220 yellow 90 220 90 230 Cylinder bore max...

Page 1132: ...0 3 050 mm 0 12 0 12 in Piston ring width compression top 1 480 1 500 mm 0 058 0 059 in Piston ring width compression bottom 1 470 1 490 mm 0 0587 0 0586 in Piston ring to groove clearance compression top 0 050 0 090 mm 0 002 0 004 in Piston ring to groove clearance compression bottom 0 030 0 080 mm 0 00118 0 00315 in Piston ring to groove clearance oil ring Snug fit Piston pin bore diameter f 21 ...

Page 1133: ...s 70 52 Exhaust manifolds a Engine front cover bolts a Drive belt tensioner bolts 25 18 A C muffler 20 15 Battery cable support brackets 20 15 Cylinder head bolt a Pulley to crankshaft bolt a EGR valve to intake manifold 25 18 EGR valve tube to exhaust manifold fittings 40 30 Intake manifold to cylinder head bolt 25 18 Main bearing cap bolt a Oil filter adapter bolts 25 18 Oil level indicator tube...

Page 1134: ...nkshaft timing bolt sensor assembly 10 89 Camshaft timing bolt sensor assembly 10 89 Fuel rail studs 10 89 Engine coolant sensor 15 11 Exhaust manifold stud to cylinder head 10 13 7 10 Throttle body adaptor bolts a Throttle body bolts 10 89 Idle air control valve 10 89 RFI capacitor nut 10 89 Generator bolts 25 18 Oil pan drain plug 14 10 Water bypass tube bracket bolt 25 18 Subframe bolts 115 85 ...

Page 1135: ......

Page 1136: ...DESCRIPTION AND OPERATION Engine SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual ...

Page 1137: ......

Page 1138: ...Item Part Number Description 1 6150 Piston ring 2 6159 Piston ring 3 6159 Piston ring 4 6110 Piston 5 6135 Piston pin 6 6211 Connecting rod bearing 7 6214 Connecting rod bolt 8 6152 Piston ring ...

Page 1139: ...le body gasket 27 9A589 Throttle body gasket 28 N807309 Bolt 3 req d 29 9728 Bracket 30 N806154 Bolt 5 req d 31 9D476 EGR valve gasket 32 9D460 EGR valve 33 W701625 Bolt 2 req d 34 N811017 Stud bolt 4 req d 35 9F792 Fuel injection supply manifold 36 9D477 EGR valve to exhaust manifold tube 37 9E498 Main emission vacuum control connector 38 12A522 Engine control sensor extension wire 39 N806459 Dow...

Page 1140: ...connector 67 10884 Water temperature indicator sender unit 68 N808130 Bolt 9 req d 69 N806807 O ring 70 N807309 Bolt 2 req d 71 12A366 Coil on plug 8 req d 72 9F593 Fuel injector 73 8575 Water thermostat 74 9424 Intake manifold 75 N806139 Bolt 76 N806164 Washer 77 6256 Camshaft sprocket 78 6265 Camshaft sprocket spacer 79 N807352 Bolt 4 req d 80 6A505 Valve cover 81 6758 Crankcase ventilation tube...

Page 1141: ...f key 110 6333 Crankshaft main bearing 5 req d 111 6A341 Crankshaft thrust washer 3 req d 112 6C357 Crankshaft main bearing side bolt 10 req d 113 6010 Cylinder block 114 9439 Intake manifold gasket 2 req d 115 6083 Head gasket 116 6505 Exhaust valve 8 req d 117 6507 Intake valve 8 req d 118 87838 Pipe plug 8 req d 119 12405 Spark plug 8 req d 120 6F087 Dowel 121 9431 Exhaust manifold 122 6C501 Va...

Page 1142: ...req d 150 6268 Timing chain belt 151 6K297 Timing chain guide 152 N804958 Bolt 4 req d 153 6A338 Crankshaft main bearing 4 req d 154 6A346 Crankshaft main bearing cap dowel pin 10 req d 155 6345 Crankshaft main bearing cap bolt 9 req d 156 N806155 Bolt 2 req d 157 W701240 Bolt 16 req d 158 6675 Oil pan 159 6710 Oil pan gasket 160 N605904 Bolt 161 6622 Oil pump screen cover and tube 162 N806180 Spa...

Page 1143: ...ial multiport fuel injection SFI aluminum cylinder heads 6049 cast iron 90 degree V shaped cylinder block individual ignition coils for each spark plug composite material intake manifold large bore throttle body N605919 Bolt 174 18663 Heater water tube 175 N806007 Dowel 2 req d 176 N807198 Dowel 2 req d 177 N806168 Bolt 6 req d 178 6375 Flywheel automatic transmission 179 6310 Crankshaft oil sling...

Page 1144: ......

Page 1145: ...GNOSIS AND TESTING Engine For basic mechanical concerns refer to Section 303 00 Refer to the Powertrain Control Emissions Diagnosis PC ED manual SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual ...

Page 1146: ...or additional information refer to Section 303 12 3 Disconnect the fuel line For additional information refer to Section 310 00 4 Disconnect the upper radiator hose from the water outlet connector 5 Disconnect and remove the upper radiator hose 6 Disconnect the accelerator cable speed control actuator cable and return spring SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual ...

Page 1147: ...acket out of the way 8 Remove the breather tube 9 Disconnect the evaporative emissions return line 10 Disconnect the differential pressure feedback EGR electrical connector 11 Disconnect the hoses from the differential pressure feedback EGR transducer ...

Page 1148: ...electrical connector 13 Disconnect the EGR vacuum regulator solenoid vacuum supply 14 Remove the bolts retaining the EGR vacuum regulator solenoid bracket to the intake manifold 15 Disconnect the exhaust gas recirculation EGR tube from the EGR valve ...

Page 1149: ...se ventilation PCV hose from the base of the throttle body and spacer assembly 17 Disconnect the hose from the PCV valve 18 Disconnect the vacuum hose from the EGR valve 19 Disconnect the idle air control IAC valve electrical connector ...

Page 1150: ...e of the throttle body adapter 21 Disconnect the throttle position sensor TPS electrical connector 22 Remove the bolts 23 Remove the throttle body and adapter as an assembly Inspect and clean the sealing surfaces The gasket is reusable if not damaged ...

Page 1151: ... sensor electrical connector and the vacuum hose 25 Disconnect the fuel charging ground wire 26 Disconnect the ignition coils and the fuel injectors 27 Disconnect the climate control vacuum supply hoses and remove the vacuum harness ...

Page 1152: ...28 Remove the four studs 29 Remove the injectors and fuel injection supply manifold as an assembly 30 Remove the ignition coils 31 Disconnect the battery terminal ...

Page 1153: ...32 Remove the generator support brace 33 Disconnect the electrical connector 34 Remove the generator 35 Disconnect the heater hose ...

Page 1154: ...ne harness and position it out of the way 37 Disconnect the water temperature indicator sender 38 Remove the water outlet connector 39 Remove the water thermostat and the O ring Inspect the O ring and discard if necessary ...

Page 1155: ...shown remove the intake manifold and gaskets Installation 1 Install the intake manifold and gaskets tighten the bolts in the sequence shown 2 NOTE The O ring is to be installed on the top of the thermostat Install the water thermostat and the O ring Install a new O ring as necessary ...

Page 1156: ...3 Install the water outlet adapter 4 Connect the water temperature indicator sender 5 Position the engine harness and attach to the intake manifold in two locations 6 Connect the heater hose ...

Page 1157: ...7 Install the generator 8 Connect the electrical connector 9 Connect the battery lead 10 Install the generator support brace ...

Page 1158: ...ll the ignition coils 12 Install the fuel injection supply manifold and fuel injectors as an assembly 13 Install four studs 14 Position the vacuum harness and connect to the climate control vacuum supply hoses ...

Page 1159: ...he ignition coils and the fuel injectors 16 Connect the fuel charging ground wire 17 Connect the fuel pressure sensor electrical connector and the vacuum hose 18 Install the throttle body and adapter as an assembly ...

Page 1160: ...n the sequence shown 20 Connect the throttle position sensor TPS electrical connector 21 Connect the main vacuum supply to the base of the throttle body adapter 22 Connect the idle air control IAC valve electrical connector ...

Page 1161: ...23 Connect the vacuum hose to the EGR valve 24 Connect the hose to the PCV valve 25 Connect the PCV hose to the base of the throttle body assembly 26 Connect the EGR tube to the EGR valve ...

Page 1162: ... regulator solenoid bracket 28 Connect the EGR vacuum regulator solenoid vacuum supply 29 Connect the EGR vacuum regulator solenoid electrical connector 30 Connect the hoses to the differential pressure feedback EGR transducer ...

Page 1163: ...31 Connect the differential pressure feedback EGR electrical connector 32 Connect the evaporative emissions return line 33 Install the breather tube 34 Position the cables and install the bracket ...

Page 1164: ...urn spring 36 Connect the upper radiator hose 37 Connect the upper radiator hose to the water outlet adapter 38 Connect the fuel line For additional information refer to Section 310 00 39 Install the air cleaner outlet tube For additional information refer to Section 303 12 ...

Page 1165: ...40 Refill the engine cooling system For additional information refer to Section 303 03A or Section 303 03B ...

Page 1166: ...refer to Section 310 00 3 Separate the engine wiring harness from the valve cover studs 4 Separate the engine wiring harness from the valve cover studs 5 Remove the positive crankcase ventilation PCV hose from the valve cover and position aside SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual Material Item Specification Silicone Gasket and Sealant F7AZ 19554 EA or equivalent WSE M4G323 ...

Page 1167: ...he transmission filler tube aside 8 Remove the bolts studs and the valve cover in the sequence shown Clean and inspect the sealing surfaces 9 NOTE Apply an eight millimeter bead of silicone gasket and sealant at the intersection of the engine front cover and the cylinder head To install reverse the removal procedure ...

Page 1168: ......

Page 1169: ...level tube 6754 out of the way 2 Disconnect the breather tube 3 Separate the engine wiring harness in the locations shown SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual Material Item Specification Silicone Gasket and Sealant F7AZ 19554 EA or equivalent WSE M4G323 A4 ...

Page 1170: ...ve the bolts studs and the valve cover in the sequence shown Inspect and clean the sealing surfaces 6 NOTE Apply an eight millimeter bead of silicone gasket and sealant at the intersection of the engine front cover and the cylinder head To install reverse the removal procedure ...

Page 1171: ......

Page 1172: ...r to Section 100 02 3 Remove the bolt 4 Using the special tool remove the crankshaft pulley 6312 SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual Special Tool s Remover Crankshaft Vibration Damper 303 009 T58P 6316 D Installer Crankshaft Vibration Damper 303 102 T74P 6316 B Material Item Specification Silicone Gasket and Sealant F7AZ 19554 EA or equivalent WSE M4G323 A4 ...

Page 1173: ...uff key slot on the crankshaft pulley 2 Using the special tool install the crankshaft pulley 3 Install the washer and the bolt Tighten the bolt in four stages Stage 1 Tighten the bolt to 90 Nm 66 lb ft Stage 2 Loosen the bolt one full turn Stage 3 Tighten the bolt to 50 Nm 37 lb ft Stage 4 Tighten the bolt an additional 90 degrees ...

Page 1174: ...4 Lower the vehicle 5 Install the drive belt For additional information refer to Section 303 05 ...

Page 1175: ...the crankshaft front oil seal SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual Special Tool s Crankshaft Seal Installer Aligner 303 335 T88T 6701 A Front Cover Seal Remover 303 107 T74P 6700 A Crankshaft Seal Installer 303 635 Crankshaft Damper Replacer 303 102 T74P 6316 B Material Item Specification Super Premium SAE 5W 20 Engine Oil XO 5W20 QSP or equivalent WSS M2C153 H ...

Page 1176: ...er and the crankshaft front oil seal inner lip with clean engine oil 2 Using the special tools install the crankshaft front oil seal into the engine front cover 3 Install the crankshaft pulley For additional information refer to Crankshaft Pulley ...

Page 1177: ......

Page 1178: ...onal information refer to Section 303 03A or Section 303 03B 4 Remove the accessory drive belt For additional information refer to Section 303 05 5 Remove bolts 1 and the water pump pulley 2 6 Remove the nut and position the A C muffler aside SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual Material Item Specification Silicone Gasket and Sealant F7AZ 19554 EA or equivalent WSE M4G323 A4...

Page 1179: ...mation refer to Section 100 02 8 Remove the bolts and position the power steering pump aside 9 Disconnect the crankshaft position CKP sensor electrical connector 10 Drain the engine oil 11 Remove the two support nuts and position the battery cable aside ...

Page 1180: ...l information refer to Crankshaft Front Oil Seal in this section 13 Remove the front oil pan bolts 14 Lower the vehicle 15 Remove the bolts and position the power steering reservoir aside 16 Disconnect the camshaft position CMP sensor electrical connector ...

Page 1181: ...t idler pulleys 18 Remove the engine front cover bolts and the studs Discard the gaskets Clean and inspect the sealing surfaces Installation 1 Apply silicone gasket and sealant in the locations shown 2 Install the engine front cover ...

Page 1182: ...lot M8 x 1 25 x 50 M6 x 1 x 10 7 N808586 Stud and Washer Hex Head Pilot M8 x 1 25 x 60 M6 x 1 x 26 8 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 9 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 10 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 11 N806300 Stud Hex Shldr Pilot M8 x 1 25 x 65 M8 x 1 25 x 26 12 W706560 Stud Hex Head Pilot M8 x 1 25 x 65 M8 x 1 25 x 16 13 N806300 Stud Hex S...

Page 1183: ...shaft front oil seal For additional information refer to Crankshaft Front Oil Seal in this section 7 Tighten the four oil pan bolts in the sequence shown Stage 1 Tighten to 2 Nm 18 lb in Stage 2 Tighten to 20 Nm 15 lb ft Stage 3 Tighten an additional 60 degrees 8 Install the drain plug ...

Page 1184: ...Position the power steering reservoir and install the bolts 10 Connect the CKP sensor electrical connector 11 Position the A C muffler and tighten the nut 12 Install the power steering pump and the bolts ...

Page 1185: ...y and the bolts 16 Install the cooling fan For additional information refer to Section 303 03A or Section 303 03B 17 Install the accessory drive belt For additional information refer to Section 303 05 18 Install the valve covers For additional information refer to Valve Cover RH and Valve Cover LH in this section 19 Position the radio ignition interference capacitors and install the nuts ...

Page 1186: ...20 Fill the crankcase with clean engine oil ...

Page 1187: ... cover For additional information refer to Engine Front Cover in this section 2 Remove the crankshaft sensor ring from the crankshaft 3 Disconnect the eight ignition coil electrical connectors SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual Special Tool s Compressor Valve Spring 303 567 T97P 6565 AH Holding Tool Crankshaft 303 448 T93P 6303 A Aligner Camshaft Position 303 557 T96T 6256...

Page 1188: ...ark plug wells before removing the spark plugs Remove the spark plugs 6 NOTE Rotate the camshaft to the base circle of the camshaft lobe before removing the followers Keep the roller followers in order when removing Using the special tool remove the 16 roller followers Rotate the crankshaft and camshaft as necessary ...

Page 1189: ...7 Remove the bolts and the LH timing chain tensioner 8 Remove the bolts and the RH timing chain tensioner ...

Page 1190: ...hain tensioner arm from the dowel pins 10 Remove the timing chains and the crankshaft sprocket 11 Remove the timing chain guides 1 Remove the bolts 2 Remove the LH timing chain guide 3 Remove the bolts 4 Remove the RH timing chain guide ...

Page 1191: ...12 NOTE RH shown LH similar Install the special tool 13 NOTE RH shown LH similar Remove the bolt and the camshaft gear Installation ...

Page 1192: ...n edge of a vise 2 While holding the ratchet mechanism push the ratchet arm back into the tensioner housing 3 Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation 4 If the copper links are not visible mark one link on one end and one link on the other end and use as timing marks ...

Page 1193: ... bolts in two stages Stage 1 Tighten the bolt to 40 Nm 30 lb ft Stage 2 Tighten the bolt an additional 90 degrees 1 4 turn 6 Remove the special tool 7 Using the special tool position the crankshaft so the number one cylinder is at TDC 8 Remove the special tool ...

Page 1194: ...the LH inner timing chain on the crankshaft sprocket aligning the copper link with the dot on the crankshaft sprocket Install the LH inner timing chain on the camshaft sprocket aligning the copper link with the dot on the camshaft sprocket Install the RH outer timing chain on the crankshaft sprocket aligning the copper link with the dot on the crankshaft sprocket Install the RH outer timing chain ...

Page 1195: ...ks are lined up with the dots on the crankshaft sprocket and the camshaft sprockets 13 NOTE The LH timing chain tensioner arm has a bump near the dowel hole for identification Position the LH and the RH timing chain tensioner arm on the dowel pins ...

Page 1196: ...14 Position the RH timing chain tensioner and install the bolts 15 Position the LH timing chain tensioner and install the bolts ...

Page 1197: ...ensioners 17 NOTE Rotate the camshaft to the base circle of the camshaft lobe before installing the roller followers NOTE Keep all the roller followers in order when installing Using the special tool install the 16 roller followers 18 Install the eight spark plugs ...

Page 1198: ...oils and bolts 20 Connect the eight ignition coil electrical connectors 21 Install the crankshaft sensor ring on the crankshaft 22 Install the engine front cover For additional information refer to Engine Front Cover in this section ...

Page 1199: ......

Page 1200: ... cylinder any loss of air pressure will allow the valve to fall into the cylinder If air pressure must be removed support the valve prior to removal Use compressed air in the cylinder to hold both valves in position 5 Using the special tool compress the valve spring 6513 SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual Special Tool s Valve Spring Compressor 303 452 T93P 6565 AR Valve St...

Page 1201: ...move the valve stem seals 1 Remove the valve spring retainer keys 2 Remove the valve spring retainers 3 Remove the valve springs 4 Remove the valve stem seals 7 NOTE Lubricate the lip of the new seal with clean engine oil prior to installation To install reverse the removal procedure ...

Page 1202: ...r additional information refer to Camshaft Roller Follower in this section 2 Remove the eight hydraulic lash adjusters 3 Inspect the lash adjusters For additional information refer to Section 303 00 4 To install reverse the removal procedure SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual ...

Page 1203: ...of the cylinder being serviced at the bottom of the stroke and the camshaft lobe at base circle 3 Using the special tool compress the intake valve spring 4 Remove the roller follower from the intake valve SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual Special Tool s Compressor Valve Spring Intake 303 452 T93P 6565 AR Compressor Valve Spring Exhaust 303 567 T97P 6565 AH ...

Page 1204: ...e camshaft roller follower from the exhaust valve 7 Repeat Steps 2 3 and 4 to remove all the necessary roller followers Inspect roller finger followers and camshafts For additional information refer to Section 303 00 Installation 1 To install reverse the removal procedure ...

Page 1205: ......

Page 1206: ...ection 2 Remove the roller followers For additional information refer to Camshaft Roller Follower in this section 3 Remove the bolts and camshaft bearing caps 4 Remove the camshaft 5 NOTE Tighten the camshaft bearing cap bolts in the sequence shown To install reverse the removal procedure SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual ...

Page 1207: ......

Page 1208: ...ll the special tools 3 Raise and support the vehicle For additional information refer to Section 100 02 4 Remove the LH and RH side engine mount nuts SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual Special Tool s Lifting Bracket Engine 303 D088 D93P 6001 A2 Support Bar Engine 303 290 A ...

Page 1209: ...motor For additional information refer to Section 303 06 10 Separate the exhaust at the exhaust manifold For additional information refer to Section 309 00 11 Remove the exhaust manifold 1 Remove the exhaust manifold nuts 2 Remove the exhaust manifold 3 Remove the exhaust manifold gasket and discard 12 NOTE Tighten the exhaust manifold nuts in the sequence shown To install reverse the removal proc...

Page 1210: ......

Page 1211: ...ll the special tools 3 Raise and support the vehicle For additional information refer to Section 100 02 4 Remove the LH and RH side engine mount nuts SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual Special Tool s Lifting Bracket Engine 303 D088 D93P 6001 A2 Support Bar Engine 303 290 A ...

Page 1212: ...the exhaust at the exhaust manifold For additional information refer to Section 309 00 9 Disconnect the exhaust gas recirculation EGR tube at the exhaust manifold 10 Remove the exhaust manifold 1 Remove the exhaust manifold nuts 2 Remove the exhaust manifold 3 Remove the exhaust manifold gasket ...

Page 1213: ...11 To install reverse the removal procedure 1 Tighten the exhaust manifold nuts in the sequence shown ...

Page 1214: ... and support the vehicle For additional information refer to Section 100 02 4 Drain the engine oil 5 Disconnect the oil pressure sensor electrical connector SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual Material Item Specification Super Premium SAE 5W 20 Motor Oil XO 5W20 QSP or equivalent WSS M2C153 H Premium Engine Coolant VC 4A In Canada CXC 10 In Oregon VC 5 or equivalent ESE M97...

Page 1215: ... the oil filter adapter 6881 1 Remove the oil bypass filter 2 Remove the bolts 3 Remove the oil filter adapter 4 Clean and inspect the sealing surfaces 8 To install reverse the removal procedure 9 Tighten the oil pressure sensor in two stages ...

Page 1216: ...Tighten to 14Nm 10 lb ft Tighten an additional 180 ...

Page 1217: ...2 Remove the LH exhaust manifold For additional information refer to Exhaust Manifold LH in this section 3 Remove the bolt 4 Remove the oil level indicator tube 5 To install reverse the removal procedure Install a new oil level indicator tube seal SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual ...

Page 1218: ......

Page 1219: ...stang Workshop Manual Special Tool s Compressor Coil Spring 204 D001 D78P 5310 A Support Bar Engine 303 290 A Lifting Bracket Engine 303 D087 D93P 6001 A1 Lifting Bracket Engine 303 D088 D93P 6001 A2 Material Item Specification Metal Surface Cleaner F4ZA 19A536 RA or equivalent WSE M5B392 A Silicone Gasket and Sealant F7AZ 19554 EA or equivalent WSE M4G323 A4 Super Premium SAE 5W 20 Motor Oil XO 5...

Page 1220: ...l 5 Using the special tools support the engine 6 Raise and support the vehicle For additional information refer to Section 100 02 7 Remove the two engine mount nuts 8 Lower the vehicle 9 Using the special tool raise the engine ...

Page 1221: ...cle For additional information refer to Section 100 02 11 Drain the engine oil Remove the oil pan drain plug 12 Using the special tool compress the front coil springs 13 Position a safety stand 14 Remove the four engine mount bolts ...

Page 1222: ...etely remove the bolts Loosen the front subframe bolts 16 Lower the front subframe 17 NOTE Be careful when removing the oil pan gasket It may be reusable Inspect the oil pan gasket for damage Remove the oil pan and gasket ...

Page 1223: ...o sign of wetness or four minutes whichever is longer Failure to follow this procedure can result in future oil leakage Apply the silicone gasket and sealant at the rear oil seal retainer to cylinder block sealing surface 3 NOTE If the oil pan is not secured within four minutes the sealant must be removed and the sealing area cleaned with metal surface cleaner Allow to dry until there is no sign o...

Page 1224: ... in the sequence shown in three stages Stage 1 Tighten to 2 Nm 18 lb in Stage 2 Tighten to 20 Nm 15 lb ft Stage 3 Tighten an additional 60 degrees 6 Install the oil pan drain plug 7 Raise the front subframe into position ...

Page 1225: ...8 Install the two upper subframe bolts 9 Install the two lower subframe bolts 10 Install the engine mount bolts 11 Position the safety stand aside ...

Page 1226: ...release the tension from the front coil springs and remove the special tool 13 Install the engine mount nuts 14 Lower the vehicle 15 Using the special tools lower the engine and remove the special tool 16 Remove the special tool ...

Page 1227: ...17 Fill the engine crankcase with clean engine oil ...

Page 1228: ...ts For additional information refer to Section 308 03A or Section 308 03B 2 Remove the bolts and the flywheel Installation 1 To install reverse the removal procedure Tighten the bolts in the sequence shown SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual ...

Page 1229: ......

Page 1230: ... For additional information refer to Section 307 01 2 Remove the six bolts retaining the flexplate to crankshaft and remove the flexplate 3 To install reverse the removal procedure Tighten the bolts in the sequence shown SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual ...

Page 1231: ......

Page 1232: ... 6701 DH Remover Crankshaft Rear Oil Seal 303 519 T95P 6701 EH Installer Crankshaft Rear Oil Seal 303 516 T95P 6701 BH Remover Crankshaft Rear Oil Slinger 303 514 T95P 6701 AH Installer Crankshaft Rear Oil Slinger 303 517 T95P 6701 CH Impact Slide Hammer 100 001 T50T 100 A Material Item Specification Super Premium SAE 5W 20 Engine Oil XO 5W20 QSP or equivalent WSS M2C153 H ...

Page 1233: ...special tools remove the crankshaft oil slinger 3 Using the special tools remove the crankshaft rear oil seal 6701 Installation 1 Using the special tools install the crankshaft rear oil seal Lubricate the oil seal using clean engine oil 2 Using the special tool install the crankshaft oil slinger ...

Page 1234: ...3 Install the flywheel For additional information refer to Flywheel in this section ...

Page 1235: ...all the special tools 3 Remove the starter For additional information refer to Section 303 06 4 Remove the two engine mount nuts SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual Special Tool s Lifting Bracket Engine 303 D088 D93P 6001 A2 Support Bar Engine 303 290 A ...

Page 1236: ...ehicle 6 Using the special tools raise the engine 7 Raise and support the vehicle For additional information refer to Section 100 02 8 Remove the engine mount Installation 1 To install reverse the removal procedure ...

Page 1237: ......

Page 1238: ...e special tools 3 Raise and support the vehicle For additional information refer to Section 100 02 4 Remove the two engine mount nuts SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual Special Tool s Lifting Bracket Engine 303 D088 D93P 6001 A2 Support Bar Engine 303 290 A ...

Page 1239: ...ehicle 6 Using the special tools raise the engine 7 Raise and support the vehicle For additional information refer to Section 100 02 8 Remove the engine mount Installation 1 To install reverse the removal procedure ...

Page 1240: ......

Page 1241: ...Remover Crankshaft Front Oil Seal 303 107 T74P 6700 A Engine Lift Bracket Set 303 DS086 D93P 6001 A Compressor Valve Spring Exhaust 303 567 T97P 6565 AH Compressor Spacer Valve Spring 303 382 T91P 6565 AH Remover Installer Cylinder Head 303 572 T97T 6000 A Material Item Specification Motorcraft Silicone Gasket Remover ZC 30 Motorcraft Metal Surface Prep ...

Page 1242: ...e For additional information refer to Engine in the Removal portion of this section 2 Remove the flywheel 3 Remove the separator plate 4 Mount the engine on a suitable engine stand 5 NOTE RH shown LH similar Remove the RH and LH lifting eyes ZC 31 ...

Page 1243: ...ure feedback exhaust gas recirculation EGR electrical connector 8 Disconnect the hoses from the differential pressure feedback EGR transducer 9 Remove the EGR vacuum regulator solenoid 1 Remove the vacuum lines 2 Remove the electrical connector 3 Remove the bolts ...

Page 1244: ...ect the EGR tube from the EGR valve 11 Disconnect the positive crankcase ventilation PCV hose from the base of the throttle body 12 Remove the PCV valve and hose as an assembly 13 Remove the engine wiring harness ...

Page 1245: ...on coils 8 6 To engine coolant temperature sensor 7 To throttle position sensor 8 To idle air control valve 9 To EGR vacuum regulator 10 To differential pressure feedback EGR 11 To fuel pressure regulator 12 Fuel injection ground 13 To generator 14 To camshaft position sensor 15 To body 16 To heated oxygen sensor 2 17 Engine bulkhead connector 18 To low coolant sensor 19 To body 20 To power distri...

Page 1246: ...e body bolts 16 NOTE The gasket is reusable if not damaged Remove the throttle body and adapter as an assembly Inspect and clean the sealing surfaces 17 Remove the ignition coils 18 Remove the radio interference capacitors ...

Page 1247: ...Remove the power steering reservoir and bracket as an assembly 1 Disconnect the supply line from the pump 2 Remove the 3 bolts and the reservoir and bracket 21 Remove the upper generator support bracket 22 Remove the bolts and the generator ...

Page 1248: ...23 Remove the coolant outlet adapter 24 Remove the thermostat and O ring 25 Remove the bolts in the sequence shown and remove the intake manifold 26 Remove the intake manifold gaskets ...

Page 1249: ...e discs or other abrasive means to clean sealing surfaces These tools will cause scratches and gouges which make leak paths Clean the sealing surfaces 28 Remove the coolant bypass tube 1 Remove the nut 2 Remove the coolant bypass tube 29 Remove the RH engine mount ...

Page 1250: ... engine block Install the drain plugs when finished 31 Remove the four bolts and the power steering pump RH cylinder head 32 Remove the RH exhaust manifold 1 Remove the RH exhaust manifold nuts 2 Remove the RH exhaust manifold 3 Remove the RH exhaust manifold gasket and discard ...

Page 1251: ...e EGR tube at the exhaust manifold 34 Remove the LH exhaust manifold 1 Remove the LH exhaust manifold nuts 2 Remove the LH exhaust manifold 3 Remove the LH exhaust manifold gasket and discard 35 Remove the oil level indicator tube bolt ...

Page 1252: ...g tool to remove all traces of old sealant NOTE The bolts are part of the valve cover and should not be removed RH valve cover shown LH valve cover similar Remove the RH and LH valve covers Fully loosen the bolts and remove the valve covers Clean the valve cover mating surface of the cylinder heads with silicone gasket remover and metal surface prep Follow the directions on the packaging Inspect t...

Page 1253: ...cial tool between the valve spring coils to prevent valve stem seal damage 41 NOTE Rotate the camshaft to see the base circle of the camshaft s lobe before removing the followers Keep roller followers in order when removing Use the special tool to compress the valve springs and remove the 16 camshaft roller followers Rotate the camshaft and crankshaft as necessary 42 Remove the crankshaft pulley b...

Page 1254: ...e the crankshaft pulley 44 Remove the coolant pump pulley 1 Remove the coolant pump pulley bolts 2 Remove the coolant pump pulley 45 Remove the bolts and belt idler pulleys 46 Using the special tool remove the engine front cover seal ...

Page 1255: ...kets clean and inspect the sealing surfaces CAUTION Since the engine is not free wheeling if the crankshaft or the camshafts are moved in any manner during removal and installation the crankshaft and the camshafts must be re synchronized 49 Remove the crankshaft sensor ring from the crankshaft ...

Page 1256: ...e bolts 2 Remove the timing chain tensioners 3 Remove the timing chain tensioner arms 52 Remove the LH and RH timing chains and the crankshaft sprocket Remove the RH timing chain from camshaft sprocket Remove the RH timing chain from the crankshaft sprocket Remove the LH timing chain from the camshaft sprocket Remove the LH timing chain and crankshaft sprocket ...

Page 1257: ...53 NOTE LH shown RH similar Remove the bolts and the timing chain guides 54 NOTE LH shown RH similar Install the lifting handles to the RH and LH cylinder heads ...

Page 1258: ...t dropped into the engine CAUTION The cylinder head bolts must be discarded and new bolts installed They are tighten to yield designed and cannot be reused CAUTION Do not use metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges that make leak paths Use a plastic scraping tool to remove all traces of the head g...

Page 1259: ... bolts installed They are tighten to yield designed and cannot be reused CAUTION Do not use metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges that make leak paths Use a plastic scraping tool to remove all traces of the head gasket CAUTION Aluminum surfaces are soft and can be scratched easily Never place th...

Page 1260: ...Apply silicone gasket remover following package directions and allow to set for several minutes 3 Remove the silicone gasket remover with a plastic scraper A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain 4 Apply metal surface prep following package directions to remove any remaining traces of oil or coolant and to prepare the...

Page 1261: ......

Page 1262: ... 5 Remove the degas bottle For additional information refer to Section 303 03A or Section 303 03B 6 Recover the A C system For additional information refer to Section 412 00 7 Disconnect the fuel lines For additional information refer to Section 310 00 8 Disconnect the upper radiator hose from the water outlet connector SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual Special Tool s Sup...

Page 1263: ...le cable speed control actuator cable and the return spring 10 Remove the bolts and position the cables and bracket out of the way 11 Disconnect the climate control vacuum supply hoses 12 Disconnect the two heater water hoses ...

Page 1264: ...13 Disconnect the engine bulkhead connector 14 Separate the harness in three locations 15 Disconnect the electrical connector 16 Remove the safety clip from the manifold suction tube ...

Page 1265: ...connect the A C manifold suction tube 18 Disconnect the A C pressure cycle switch 19 Remove the nut and separate the liquid tube from the A C condenser 20 Disconnect the power steering hose from the reservoir ...

Page 1266: ...21 Remove the bolt and the body ground 22 Separate the fuse link 23 Disconnect the connector 24 Disconnect the ground connector ...

Page 1267: ...25 Slide the access cover up 26 Remove the nut and the battery leads 27 Disconnect the connector 28 Separate the degas sensor lead from the battery tray ...

Page 1268: ...cle For additional information refer to Section 100 02 30 Drain the engine oil 31 Disconnect the RH heated oxygen sensor connector 32 Disconnect the LH heated oxygen sensor connector 33 Remove the four exhaust manifold flange nuts ...

Page 1269: ...fer to Section 303 06 35 Remove the nine bell housing bolts 36 Remove the bolt and the body ground 37 Remove the power steering pump For additional information refer to Section 211 02 38 Lower the vehicle 39 Remove the safety clip from the suction tube ...

Page 1270: ...suction tube at the receiver drier and remove the tube 41 Remove the safety clip from the line at the evaporator core 42 Disconnect the tube from the evaporator core 43 Remove the nut and remove the tube from the vehicle ...

Page 1271: ...e For additional information refer to Section 100 02 46 NOTE The manifold will not be removed from the vehicle in this step Remove the six exhaust manifold nuts 47 Lower the vehicle 48 Remove the generator For additional information refer to Section 414 02 49 Install the special tool ...

Page 1272: ...stallation of the engine lift brackets Using a suitable floor crane raise the engine to remove the exhaust manifold 51 Install the RH and LH special tool 52 NOTE Before carrying out this step it will be necessary to support the transmission with a floor jack and a block of wood Install the special tool ...

Page 1273: ...ket Raise the engine slightly to gain access to the transmission wiring support bracket 54 NOTE Adjust the transmission support jack as necessary to aid in the removal of the engine Using the special tool remove the engine from the vehicle ...

Page 1274: ...ankshaft Rear Oil Slinger 303 514 T95P 6701 AH Remover Crankshaft Rear Oil Seal 303 519 T95P 6701 EH Remover Crankshaft Vibration Damper 303 009 T58P 6316 D Installer Connecting Rod 303 442 T93P 6136 A Remover Crankshaft Front Oil Seal 303 107 T74P 6700 A Engine Lift Bracket Set 303 DS086 D93P 6001 EA Cylinder Ridge Reamer 303 016 T64L 6011 EA ...

Page 1275: ...the flywheel 2 Remove the separator plate 3 Using the special tools remove the crankshaft rear oil slinger Compressor Valve Spring Exhaust 303 567 T97L 6565 AH Remover Installer Cylinder Head 303 572 T97T 6000 A ...

Page 1276: ...4 Using the special tools remove the rear main seal 5 Remove the rear seal retainer plate 6 Mount the engine on a work stand 7 NOTE RH shown LH similar Remove the RH and LH lifting eyes ...

Page 1277: ...ial pressure feedback EGR electrical connector 10 Disconnect the hoses from the differential pressure feedback EGR transducer 9J434 11 Remove the EGR vacuum regulator solenoid 1 Remove the vacuum hoses 2 Remove the electrical connector 3 Remove the bolts ...

Page 1278: ...e exhaust gas recirculation EGR tube from the EGR valve 13 Disconnect the positive crankcase ventilation PCV hose from the base of the throttle body 14 Disconnect the PCV valve hose 15 Remove the engine wiring harness ...

Page 1279: ...n coils 8 6 To engine coolant temperature sensor 7 To throttle position sensor 8 To idle air control valve 9 To EGR vacuum regulator 10 To differential pressure feedback EGR 11 To fuel pressure regulator 12 Fuel injection ground 13 To generator 14 To camshaft position sensor 15 To body 16 To heated oxygen sensor 2 17 Engine bulkhead connector 18 To low coolant sensor 19 To body 20 To power distrib...

Page 1280: ...e body bolts 18 NOTE The gasket is reusable if not damaged Remove the throttle body and adapter as an assembly Inspect and clean the sealing surfaces 19 Remove the ignition coils 20 Remove the radio interference capacitors ...

Page 1281: ...ccessory drive belt 22 Remove the power steering reservoir bracket as an assembly 1 Disconnect the supply line from the pump 2 Remove the three bolts and reservoir 23 Remove the upper generator support bracket 24 Remove the bolts and the generator ...

Page 1282: ...25 Remove the water outlet connector 26 Remove the water thermostat and O ring 27 Remove the bolts in the sequence shown and remove the intake manifold 28 Remove the intake manifold gaskets ...

Page 1283: ...brasive discs or other means to clean sealing surfaces These tools cause scratches and gouges which make leak paths Remove the water bypass tube 1 Remove the nut 2 Remove the water bypass tube 30 NOTE RH shown LH similar Remove the RH and the LH engine mount ...

Page 1284: ...de similar Using a suitable container drain coolant from the engine block Install the drain plugs when finished 32 Remove the four bolts and the power steering pump 33 Remove the compressor 1 Remove the bolts 2 Remove the compressor ...

Page 1285: ...e the oil filter adapter 4 Clean and inspect the sealing surfaces 35 Remove the LH exhaust manifold 1 Remove the exhaust manifold nuts 2 Remove the exhaust manifold 3 Remove the exhaust manifold gasket and discard 36 Disconnect the exhaust recirculation EGR tube 9D477 at the exhaust manifold ...

Page 1286: ... 2 Remove the exhaust manifold 3 Remove the exhaust manifold gasket and discard 38 Clean and inspect the exhaust manifolds For additional information refer to Section 303 00 39 Remove the oil level indicator tube bolt 40 Remove the bolt and the oil level indicator tube ...

Page 1287: ...41 Remove valve cover Remove the fasteners Remove the valve cover 42 Remove valve cover Remove the fasteners Remove the valve cover ...

Page 1288: ...k plugs 44 NOTE Rotate the camshaft to the base circle of the camshaft lobe before removing followers Keep roller followers in order when removing Use special tool to compress the valve springs 6513 and remove the 16 camshaft roller followers Rotate the camshaft and the crankshaft as necessary 45 Remove the crankshaft pulley bolt 46 Using the special tool remove the crankshaft pulley ...

Page 1289: ...mp pulley 1 Remove the water pump pulley bolts 2 Remove the water pump pulley 48 Remove the bolts and belt idler pulleys 49 NOTE The gasket can be reused if not damaged Remove the oil pan Remove the bolts Remove the oil pan ...

Page 1290: ...r Discard the gaskets Clean and inspect the sealing surfaces CAUTION Since the engine is not free wheeling if the crankshaft or the camshafts are moved in any manner during removal and installation the crankshaft and the camshafts must be re synchronized 52 Remove the crankshaft sensor ring from the crankshaft ...

Page 1291: ...cylinder heads are installed is the crankshaft or the camshaft to be rotated Severe piston and valve damage can occur CAUTION Do not remove the special tool from the camshafts Remove the LH and RH timing chains and the crankshaft sprocket Remove the RH timing chain from the camshaft sprocket Remove the RH timing chain from the crankshaft sprocket Remove the LH timing chain from the camshaft sprock...

Page 1292: ...55 NOTE The LH is shown and the RH is similar Remove the bolts and the timing chain guides 56 NOTE One side shown other side similar Install the lifting handles to the RH and LH cylinder heads ...

Page 1293: ...the bolts 2 Remove the cylinder heads 58 CAUTION Do not use metal scrappers wire brushes power abrasive discs or other abrasive means to clean gasket surfaces These tools cause scratches and gouges that make leak paths Use a plastic scrapping tool to remove all traces of the head gasket 6051 Clean and inspect all of the sealing surfaces For additional information refer to Section 303 00 59 Remove ...

Page 1294: ...CAUTION Do not stamp the top of pistons as ring land damage can occur NOTE Connecting rods and rod caps should be numbered to retain correct orientation Remove the connecting rod caps for piston numbers 1 and 6 Discard the bolts ...

Page 1295: ...he ridge or carbon deposits from each cylinder using a cylinder ridge reamer following the manufacturer s instructions Remove the piston removing pistons number 1 and 6 through the top of the cylinder block 63 Repeat the previous two steps to remove the remaining pistons rotating the crankshaft 90 degrees between piston pairs 3 and 5 4 and 7 2 and 8 64 Remove the piston rings ...

Page 1296: ...aft bearing cap fasteners 1 Remove and discard the cross mounted main cap bolts 2 Loosen the jackscrews 3 Remove and discard the main cap bolts 67 Remove the main bearing cap and the crankshaft main bearings from the cylinder block 68 Remove the crankshaft crankshaft main bearings and the thrust washer ...

Page 1297: ......

Page 1298: ...oller followers SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual Special Tool s Compressor Valve Spring 303 381 T91P 6565 A Compressor Spacer Valve Spring 303 382 T91P 6565 AH Installer Valve Stem Oil Seal 303 383 T91P 6571 A Material Item Specification Super Premium SAE 5W 20 Motor Oil 5W20 QSP or equivalent WSS M2C153 H ...

Page 1299: ...alve spring 4 Remove the valves 1 Remove the valve spring retainer keys 2 Remove the valve spring retainers 3 Remove the valve spring 4 Remove the valves 5 Remove the hydraulic lash adjusters 6 Remove the bolts and the camshaft bearing caps ...

Page 1300: ...7 Remove the camshaft 6250 8 Remove the valve stem seals Assembly 1 NOTE Lubricate all moving parts with clean engine oil prior to assembly To install reverse the removal procedure ...

Page 1301: ......

Page 1302: ...pect the piston and connecting rod For additional information refer to Section 303 00 Assembly 1 NOTE Connecting rod must be installed into piston with identification markings toward front Position the connecting rod in the piston SECTION 303 01B Engine 4 6L 2V 2003 Mustang Workshop Manual Material Item Specification Super Premium SAE 5W 20 Motor Oil XO 5W20 QSP or equivalent WSS M2C153 H ...

Page 1303: ...ntification mark towards the dome 3 NOTE Assemble with end gaps up Using a suitable tool install the piston oil control segment ring spacer 4 NOTE Install one segment ring above and one segment ring below the spacer Using a suitable tool install the piston oil control segment rings 5 Orient the upper compression ring gap to the center line at the rear of the piston parallel to the wrist pin bore 6...

Page 1304: ......

Page 1305: ...Installer Crankshaft Rear Oil Seal 303 518 T95P 6701 DH Installer Crankshaft Rear Oil Seal 303 516 T95P 6701 BH Installer Crankshaft Rear Oil Slinger 303 517 T95P 6701 CH Impact Slide Hammer 100 001 T50T 100 A Spreader Bar 303 D089 D93P 6001 A3 Lifting Bracket Engine 303 D087 D93P 6001 A1 Lifting Bracket Engine 303 D088 D93P 6001 A2 ...

Page 1306: ...316 B Installer Front Cover Oil Seal 303 335 T88T 6701 A Compressor Piston Ring 303 D032 D81L 6002 C or equivalent Holding Tool Crankshaft 303 448 T93P 6303 A Remover Installer Cylinder Head 303 572 T97T 6000 A Compressor Valve Spring 303 576 T97P 6565 AH Strap Wrench 303 D055 D85L 6000 A or equialent ...

Page 1307: ...he front of the engine block 2 Record the main bearing code found on the back of the crankshaft 3 Using the data recorded earlier and the Bearing Select Fit Chart Standard Bearings Chart Crankshaft Seal Installer 303 635 Material Item Specification Silicone Gasket and Sealant F7AZ 19554 EA or equivalent WSE M4G323 A4 Super Premium SAE 5W 20 Motor Oil XO 5W20 QSP or equivalent WSS M2C153 H ...

Page 1308: ...g code letter until the two intersect This is the required bearing grade for the number one crankshaft main bearing As an example if the engine block code letter is F and the crankshaft code letter is D the correct bearing grade for this main bearing is 2 Repeat this process for the remaining four main bearings 4 If oversize bearings are being used use the procedure in the previous step and the Be...

Page 1309: ...re clear 5 Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil 6 NOTE Do not install the upper thrust washer until the crankshaft is installed Refer to Step 3 NOTE Do not install the upper thrust washer until the crankshaft 6303 is installed Refer to Step 3 Install the crankshaft onto the upper main bearings ...

Page 1310: ... No 5 main boss 8 NOTE Rotate the jackscrews into the bearing caps enough to provide clearance to the cylinder block prior to installing the bearing caps Install the lower main bearings into the main bearing caps and lubricate them with clean engine oil 9 Install the rear main bearing cap 10 Install the remaining main bearing caps on the cylinder block and tap into place using a plastic or dead bl...

Page 1311: ...ng cap fasteners and tighten in the sequence shown Tighten to 40 Nm 30 lb ft Tighten an additional 85 95 degrees 12 Back out the jackscrews against the cylinder block in sequence shown Tighten to 5 Nm 44 lb in Tighten to 10 Nm 89 lb in ...

Page 1312: ... the sequence shown 14 Check the crankshaft end play For additional information refer to Section 303 00 15 Check the piston to cylinder block and piston ring clearances For additional information refer to Section 303 00 16 Install the piston rings ...

Page 1313: ...o not scratch the cylinder walls or the crankshaft journals with the connecting rod NOTE Only one piston and connecting rod shown others similar NOTE Make sure the crankshaft is facing forward NOTE Lubricate the piston rings cylinder walls and connecting rod bearings with clean engine oil Install the upper bearings in the connecting rod as shown ...

Page 1314: ...ngine Check that the piston connecting rod assembly is oriented with the identification marks facing the front of the engine 20 CAUTION Do not scratch the cylinder walls or the crankshaft journals with the connecting rod NOTE Make sure the crankshaft is at TDC ...

Page 1315: ... serviced Install the connecting rod bearing caps and bolts and tighten in three stages Stage 1 Tighten to 25Nm 18 lb ft Stage 2 Tighten to 40Nm 30 lb ft Stage 3 Tighten an additional 90 degrees 22 Rotate the crankshaft and install the remaining piston and connecting rod assemblies 23 Check the connecting rod bearing clearance For additional information refer to Section 303 00 24 Install the oil p...

Page 1316: ...cedure can cause future oil leakage If the retainer plate was removed apply a 4 mm 0 16 in bead of silicone gasket and sealant around the rear oil seal retainer sealing surface 27 Install the rear main seal retainer plate Tighten the bolts in the sequence shown Tighten bolts 1 6 to 10 Nm 89 lb in Hand tighten bolts 7 and 8 Tighten bolts 7 and 8 to 20 Nm 15 lb ft Tighten bolts 7 and 8 an additional...

Page 1317: ...quence shown Tighten to 20 Nm 15 lb ft Rotate an additional 60 degrees 30 Install the cylinder head gaskets 31 CAUTION Cylinder head to cylinder block pre assembly must be followed exactly or damage to valves and pistons can result ...

Page 1318: ... rotated clockwise only Align the keyways as shown 32 NOTE Position the RH and the LH cylinder heads over the dowels on the cylinder head gaskets NOTE The LH is shown the RH is similar Tighten the bolts in six stages in the sequence shown Stage 1 Tighten to 40 Nm 30 lb ft Stage 2 Tighten an additional 90 degrees Stage 3 Loosen the bolts a minimum of one full turn Stage 4 Tighten to 40 Nm 30 lb ft ...

Page 1319: ...ust be followed exactly or damage to valves and pistons will result Using a vise compress the tensioner plunger 34 Install a retaining clip on the tensioner to hold the plunger in during installation 35 Remove the tensioner from the vise ...

Page 1320: ...end and one link on the other end to use as timing marks 37 Install the timing chain guides 1 Position the LH timing chain guide 2 Install and tighten the LH bolts 3 Position the RH timing chain guide 4 Install and tighten the RH bolts 38 Install the crankshaft sprocket making sure the flange faces forward ...

Page 1321: ...n the timing chains are removed and the cylinder heads are installed Severe piston and valve damage will occur CAUTION When instructed to do so rotate the crankshaft counterclockwise only Do not rotate past the position shown or severe piston and valve damage can occur NOTE The number one cylinder is at top dead center TDC when the stud on the engine block fits into the slot in the handle of the s...

Page 1322: ... the LH timing chain on the camshaft sprocket aligning the copper marked link with the timing marks on the sprocket 44 NOTE The LH timing chain tensioner arm has a bump near the dowel hole for identification Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner 45 Remove the retaining clip from the LH timing chain tensioner ...

Page 1323: ...mark on the sprocket 47 Install the RH timing chain on the camshaft sprocket aligning the copper marked link with the timing marks on the sprocket 48 Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner 49 Remove the retaining clip from the RH timing chain tensioner ...

Page 1324: ...crankshaft sprockets and the camshaft sprocket 51 NOTE Sensor ring teeth must face forward Position the crankshaft sensor ring on the crankshaft 52 NOTE The front cover must be installed within four minutes of applying sealant Apply silicone gasket and sealant in the locations shown ...

Page 1325: ...Head Pilot M8 x 1 25 x 53 2 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 3 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 4 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 5 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 6 W706508 Stud Hex Shldr Pilot M8 x 1 25 x 50 M6 x 1 x 10 7 N808586 Stud and Washer Hex Head Pilot M8 x 1 25 x 60 M6 x 1 x 26 ...

Page 1326: ...ean engine oil 8 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 9 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 10 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 11 N806300 Stud Hex Shldr Pilot M8 x 1 25 x 65 M8 x 1 25 x 26 12 W706560 Stud and Washer Hex Head Pilot M8 x 1 25 x 65 M8 x 1 25 x 16 13 N806300 Stud Hex Shldr Pilot M8 x 1 25 x 65 M8 x 1 25 x 26 14 N806300 Stud Hex Shldr Pilot ...

Page 1327: ...ll the water pump pulley and bolts 60 NOTE The crankshaft pulley must be installed within four minutes of applying sealant Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley 61 Using the special tool install the crankshaft pulley ...

Page 1328: ...kshaft pulley Install the washer and the bolt Tighten the bolt in four stages Stage 1 Tighten to 90 Nm 66 lb ft Stage 2 Loosen one full turn Stage 3 Tighten to 50 Nm 37 lb ft Stage 4 Tighten an additional 90 degrees 63 Install the LH engine mount 64 Install the RH engine mount ...

Page 1329: ... the power steering pump Position the power steering pump Install the bolts 66 Lubricate the O ring seal with PAG compressor oil YN 12C F7AZ 19589 DA or equivalent meeting Ford specification WSH M1C231 B Install the A C compressor 67 Install the oil filter adapter ...

Page 1330: ...ft roller followers 1 Install the special tool 2 Compress the valve spring 3 Install the camshaft follower 69 NOTE One spark plug shown others similar Install spark plugs 70 NOTE The RH side is shown the LH side is similar ...

Page 1331: ...sket and sealant at the intersection of the engine front cover and the cylinder head 71 NOTE RH valve cover shown LH similar Install the valve covers 72 NOTE Lubricate the O ring seal with clean engine oil Install a new O ring 73 Install the tube ...

Page 1332: ...n the sequence shown Install the LH exhaust manifold 75 Connect the lower end of the EGR tube to the LH exhaust manifold 76 Inspect the O ring seals and install new O ring seals as necessary 77 Install the water bypass tube 1 Instal the bypass tube 2 Install the nut ...

Page 1333: ...ten the bolts in the sequence shown 79 NOTE The O ring is to be installed on top of the thermostat Install the water thermostat and O ring Install a new O ring as necessary 80 Install the water outlet connector 81 Install the bolts and the generator ...

Page 1334: ...nstall the generator support brace 83 Install the accessory drive belt For additional information refer to Section 303 05 84 Install the radio interference capacitors 85 Install the ignition coils and bolts ...

Page 1335: ...ion the throttle body and install the bolts tighten in the sequence shown 87 Connect the vacuum line to the fuel pressure sensor 88 Connect the PCV hose 89 Connect the PCV hose to the base of the throttle body ...

Page 1336: ...EGR vacuum regulator solenoid 1 Install the vacuum hoses 2 Install the electrical connector 3 Install the bolts 92 Connect the hoses from the differential pressure feedback EGR transducer 93 Connect the differential pressure feedback EGR electrical connector ...

Page 1337: ...l the breather tube 95 Install the engine control sensor wiring Item Part Number Description 1 To crankshaft position sensor 2 To A C compressor 3 To radio ignition interference capacitor 2 4 To fuel injectors 8 ...

Page 1338: ...on coils 8 6 To engine coolant temperature sensor 7 To throttle position sensor 8 To idle air control valve 9 To EGR vacuum regulator 10 To differential pressure feedback EGR 11 To fuel pressure regulator 12 Fuel injection ground 13 To generator 14 To camshaft position sensor 15 To body 16 To heated oxygen sensor 2 17 Engine bulkhead connector 18 To low coolant sensor 19 To body 20 To power distri...

Page 1339: ...99 Using the special tools install the crankshaft rear oil slinger 100 Install the separator plate 101 Install the flywheel ...

Page 1340: ......

Page 1341: ...ion Damper 303 102 T74P 6316 B Installer Front Cover Oil Seal 303 335 T88T 6701 A Holding Tool Crankshaft 303 448 T93P 6303 A Spreader Bar 303 D089 D93P 6001 A3 Lifting Bracket Set Engine 303 D074 D91P 6001 A Strap Wrench 303 D055 D85L 6000 A or equivalent Compressor Valve Spring 303 567 T97P 6565 AH Compressor Spacer Valve Spring ...

Page 1342: ...ating which is crucial to the gasket s ability to seal correctly Do not scratch the gasket NOTE RH head gasket shown LH head gasket similar Install the head gasket over the dowel pins 303 382 T91P 6565 AH Remover Installer Cylinder Head 303 572 T97T 6000 A Material Item Specification Motorcraft Silicone Gasket Remover ZC 30 Motorcraft Metal Surface Prep ZC 31 Hydraulic Chain Tensioner Retaining Cl...

Page 1343: ...nder head bolts must be lightly oiled with a rag and allowed to drain for a few minutes prior to installation NOTE RH head gasket shown LH head gasket similar Install the cylinder head on the dowels and the head gasket Loosely install new bolts NOTE Position the cylinder head s over the dowels on the head gasket s 3 NOTE LH shown RH similar Tighten the bolts in six stages in the sequence shown Sta...

Page 1344: ...NOTE Lubricate the hydraulic lash adjusters with clean engine oil 5 Install the hydraulic lash adjusters in their original locations 6 CAUTION Timing chain procedures must be followed exactly or damage to the valves and pistons will result NOTE LH shown RH similar ...

Page 1345: ...tion 8 Remove the tensioner from the vise 9 If the copper links are not visible mark one link on one end and one link on the other end and use as timing marks 10 Install the timing chain guides 1 Position LH timing chain guide 2 Install and tighten the bolts 3 Position the RH timing chain guide 4 Install and tighten the RH bolts ...

Page 1346: ...sition 12 CAUTION When instructed to do so rotate the crankshaft counterclockwise only Do not rotate past the position shown or severe piston and valve damage can occur NOTE The number one cylinder is at top dead center TDC when the stud on the engine block fits into the slot in the handle of the special tool Using the special tool position the crankshaft so the number one cylinder is at TDC ...

Page 1347: ...flange faces forward 15 Position the LH inner timing chain on the crankshaft sprocket aligning the copper marked link with the timing mark on the sprocket 16 Install the LH timing chain on the camshaft sprocket aligning the copper marked link with the timing marks on the sprocket ...

Page 1348: ...stall the LH timing chain tensioner 18 Remove the retaining clip from the LH timing chain tensioner 19 Position the RH outer timing chain on the crankshaft sprocket aligning the copper marked link with the timing mark on the sprocket 20 Install the RH timing chain on the camshaft sprocket aligning the copper marked link with the timing marks on the sprocket ...

Page 1349: ...he RH timing chain tensioner 22 Remove the retaining clip from the RH timing chain tensioner 23 Make sure that the copper marked chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket 24 Install the crankshaft sensor ring on the crankshaft ...

Page 1350: ...is no sign of wetness or four minutes whichever is longer Failure to follow this procedure can cause future oil leakage Apply a bead of sealant along the head to block surface as shown 26 Install a new engine front cover gasket on the engine front cover Position the engine front cover Install the fasteners finger tight 27 Tighten the front cover fasteners in the sequence shown ...

Page 1351: ...d pilot M8 x 1 25 x 53 6 W706508 Stud hex shldr pilot M8 x 1 25 x 50 m6 x 1 x 10 7 N808586 Stud and washer hex head pilot M8 x 1 25 x 60 m6 x 1 x 26 8 N806177 Bolt hex flange head pilot M8 x 1 25 x 53 9 N806177 Bolt hex flange head pilot M8 x 1 25 x 53 10 N806177 Bolt hex flange head pilot M8 x 1 25 x 53 11 N806300 Stud hex shldr pilot M8 x 1 25 x 65 M8 x 1 25 x 26 12 W706560 Stud and washer hex h...

Page 1352: ...0 degrees 29 Install the belt idler pulleys 30 Lubricate the engine front cover and the front oil seal inner lip with clean engine oil 31 Using the special tool install the front oil seal 32 Install the coolant pump pulley and bolts ...

Page 1353: ...nkshaft pulley 34 Using the special tool install the crankshaft pulley 35 NOTE Use special tool 303 009 or a suitable strap wrench to hold the crankshaft pulley Install the washer and the bolt Tighten the bolt in four stages Stage 1 Tighten to 90 Nm 66 lb ft Stage 2 Loosen one full turn Stage 3 Tighten to 50 Nm 37 lb ft Stage 4 Tighten an additional 90 degrees ...

Page 1354: ... NOTE Only three bolts are required for installation Install the power steering pump bolts Position the power steering pump Install the bolts 38 Install the special tool between the valve spring coils to prevent valve stem seal damage ...

Page 1355: ...t roller followers in their original locations 40 Remove the special tool 41 NOTE One spark plug shown others similar Install the spark plugs 42 NOTE RH side shown LH side similar NOTE If not secured within four minutes the sealant must be removed and the sealing area cleaned To clean the sealing area use silicone gasket remover and metal surface prep Follow the directions on the packaging Failure...

Page 1356: ...43 NOTE RH valve cover shown LH similar Install the valve covers LH cylinder head 44 NOTE Lubricate the O ring seal with clean engine oil Install a new O ring ...

Page 1357: ...he LH exhaust manifold Tighten the nuts in the sequence shown 47 Connect the lower end of the exhaust gas recirculation EGR tube to the LH exhaust manifold RH cylinder head 48 Install the RH exhaust manifold Install a new exhaust manifold gasket Install the RH exhaust manifold Tighten the nuts in the sequence shown ...

Page 1358: ...Inspect O ring seals and install new O ring seals as necessary 50 Install the coolant bypass tube 1 Install the bypass tube 2 Install the nut 51 Install the intake manifold and gaskets Tighten the bolts in the sequence shown ...

Page 1359: ...ng Install a new O ring as necessary 53 Install the coolant outlet adapter 54 Install the bolts and the generator 55 Install the upper generator support bracket 56 Position the power steering reservoir and bracket then install the bolts ...

Page 1360: ... Install the accessory drive belt 58 Install the radio interference capacitors 59 Install the ignition coils and bolts 60 Position the throttle body and install the bolts tightening in the sequence shown ...

Page 1361: ...vacuum line to the fuel pressure sensor 62 Install the positive crankcase ventilation PCV valve and hose as an assembly 63 Connect the PCV hose to the base of the throttle body 64 Connect the EGR tube to the EGR valve ...

Page 1362: ...tall the vacuum lines 2 Install the electrical connector 3 Install the bolts 66 Connect the hoses from the differential pressure feedback EGR transducer 67 Connect the differential pressure feedback EGR electrical connector 68 Install the breather tube ...

Page 1363: ...ition interference capacitor 2 4 To fuel injectors 8 5 To ignition coils 8 6 To engine coolant temperature sensor 7 To throttle position sensor 8 To idle air control valve 9 To EGR vacuum regulator 10 To differential pressure feedback EGR 11 To fuel pressure regulator 12 Fuel injection ground 13 To generator 14 To camshaft position sensor ...

Page 1364: ...the special tool remove the engine from the stand 72 Install the separator plate 73 Install the flywheel 15 To body 16 To heated oxygen sensor 2 17 Engine bulkhead connector 18 To low coolant sensor 19 To body 20 To power distribution box 21 To body ...

Page 1365: ...74 Install the engine For additional information refer to Engine in the Installation portion of this section ...

Page 1366: ...et Engine 303 D088 D93P 6001 A2 Lifting Bracket Set Engine 303 D074 D91P 6001 A Material Item Specification Metal Surface Cleaner F4AZ 19A536 RA or equivalent WSE M5B392 A Silicone Gasket and Sealant F7AZ 19554 EA or equivalent WSE M4G323 A4 Super Premium SAE 5W 20 Engine Oil XO 5W20 QSP or equivalent WSS M2C153 H Premium Engine Coolant E2FZ 19549 AA In Canada CXC 10 In Oregon F5FZ 19549 CC or equ...

Page 1367: ... support jack as necessary to aid in the installation of the engine Using the special tool install the engine 2 Connect the transmission wiring to the bracket during installation 3 Remove the special tool 4 Install the special tool ...

Page 1368: ... the bottom and access for the removal of the engine lift brackets Using a suitable floor crane raise the engine 6 Remove the RH and LH special tool 7 Install new gaskets and the exhaust manifolds tighten the nuts in the sequence shown 8 Lower the engine remove the special tool ...

Page 1369: ... information refer to Section 211 02 12 Install the bolt and the body ground 13 Install the nine bell housing bolts 14 Install the starter For additional information refer to Section 303 06 15 NOTE This will need to be done as the H pipe is being positioned Connect the LH heated oxygen sensor 16 NOTE This will need to be done as the H pipe is being positioned Connect the RH heated oxygen sensor ...

Page 1370: ...ring seal must be inspected and cleaned before installation For additional information refer to Section 412 00 Install the A C line and tighten the nut 20 NOTE The O ring seal must be inspected and cleaned before installation For additional information refer to Section 412 00 Connect the line to the evaporator core ...

Page 1371: ... The O ring seal must be inspected and cleaned before installation For additional information refer to Section 412 00 Connect the line to the receiver drier 23 Install the safety clip 24 Connect the degas sensor lead to the battery tray ...

Page 1372: ...25 Connect the connector 26 Install the battery leads 27 Position the access cover 28 Connect the ground connector ...

Page 1373: ...29 Connect the connector 30 Connect the fuse link 31 Install and tighten the body ground 32 Connect the power steering line ...

Page 1374: ...For additional information refer to Section 412 00 Install the A C line 34 Connect the A C pressure cycle switch 35 NOTE The O ring seal must be inspected and cleaned before installation For additional information refer to Section 412 00 Connect the A C manifold suction line ...

Page 1375: ...36 Install the safety clip to the manifold suction line 37 Connect the electrical connector 38 Connect the harness in three locations 39 Connect the engine bulkhead connector ...

Page 1376: ...nnect the heater water hoses 41 Connect the climate control vacuum supply lines 42 Position the cables and install the bracket 43 Connect the throttle cable speed control actuator cable and the return spring ...

Page 1377: ... 47 Install the air cleaner and outlet tube For additional information refer to Section 303 12 48 Install the degas bottle For additional information refer to Section 303 03A or Section 303 03B 49 Fill the fluids to the correct levels 50 Start the engine and check for leaks Stop the engine and recheck the fluid levels 51 Recharge the A C system For additional information refer to Section 412 00 52...

Page 1378: ......

Page 1379: ...mm 3 54 in Firing order 1 3 7 2 6 5 4 8 Oil pressure 138 310 kPa Oil capacity 6 0 25 a Compression ratio 8 5 1 Cylinder Head and Valve Train Cylinder head gasket surface flatness 0 10 mm 0 004 inch max overall Combustion chamber volume 52 6 0 5 cm Valve arrangement front to rear b Intake left hand S P S P S P S P Valve arrangement front to rear Exhaust left hand E E E E E E E E Valve arrangement f...

Page 1380: ...99 lb ft 1 4228 inch Roller follower ratio 1 8 1 Hydraulic Lash Adjuster Diameter 16 000 15 988 mm 0 6299 0 6294 inch Clearance to bore 0 018 0 069 mm 0 000709 0 002717 inch Service limit 0 016 mm 1 0006299 inch Hydraulic leakdown rate c 5 25 seconds Collapsed lash adjuster gap 0 80 1 20 mm 0 0315 0 0472 inch Camshaft Theoretical valve lift 0 lash intake primary and secondary 10 0 mm 0 3937 inch T...

Page 1381: ...50 mm Piston ring end gap compression oil ring 0 65 mm Piston ring groove width compression top 1 53 1 549 mm Piston ring groove width compression bottom 1 519 1 539 mm Piston ring groove width oil ring 3 031 3 055 mm Piston ring width compression top 1 47 1 49 mm Piston ring width compression bottom 1 47 1 49 mm Piston ring width oil ring 2 854 2 984 mm Piston ring to groove clearance compression...

Page 1382: ...nnecting rod bolt a Engine front cover bolt a a a Drive belt tensioner bolts 25 18 Cylinder head bolt a Idler pulley bracket 25 18 Power steering pump bolts 25 18 Power steering hose fitting 65 48 Power steering hose bracket bolt 10 89 Pulley to crankshaft bolt a EGR valve to intake manifold a Engine coolant degas bottle bolts 10 89 Exhaust manifold studs 25 18 Generator bolts 25 18 Generator supp...

Page 1383: ... 18 EGR valve to exhaust manifold tube nuts 40 30 Power steering pump to engine 25 18 Power steering hose bracket nut 25 18 Power steering reservoir bracket fasteners 10 89 Supercharger degas bottle bolts 10 89 Camshaft cap cluster to cylinder head 10 89 Timing chain tensioner bolts primary 25 18 Timing chain tensioner bolts secondary 10 89 Ignition coil cover bolts 10 89 Generator mounting bracke...

Page 1384: ......

Page 1385: ...n codes will ensure that the correct parts are obtained These codes contain all the pertinent information relating to the dates optional equipment and revisions The Ford Master Parts Catalog contains a complete listing of the codes and their application Code Information The engine code information label located on the side of the valve cover and the front side of the valve cover contains the follo...

Page 1386: ...linder heads From the main journals the oil is routed through cross drilled passages in the crankshaft to lubricate the connecting rod bearings Controlled leakage through the crankshaft main bearings and connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls as well as the entire connecting rod piston and piston rings assembly The left cylinder head is fed from ...

Page 1387: ...peed conditions Cooling System The engine cooling system includes the following radiator water pump the electric cooling fan motor and fan blade activated by the variable control module the degas bottle which aids in maintaining the correct volume of engine coolant water thermostat upper radiator hose lower radiator hose heater water hoses Drive Belt System The 4 6L 4V DOHC engine is equipped with...

Page 1388: ...Throttle body 8 Bolts 4 req d 9 Bolts 2 req d 10 9E926 Throttle position sensor 11 N804178 Nuts 4 req d 12 Studs 4 req d 13 Spacer assembly gasket 14 9D475 Exhaust gas recirculation valve 15 Stud 16 9D477 Exhaust gas recirculation tube 17 Manifold absolute pressure sensor 18 9J460 Differential pressure feedback EGR system 19 9J459 Exhaust gas recirculation vacuum regulator 20 9J472 Vacuum accessor...

Page 1389: ...rt Number Description 1 12B637 Wiring harness 2 9C986 Fuel pulse damper 3 9F792 Fuel injection supply manifold 4 9F593 Fuel injector 5 Stud 6 9D475 Exhaust gas recirculation valve 7 W701232 Bolt 8 N806979 Stud ...

Page 1390: ...intake manifold 14 9L438 Coolant intake manifold gasket 15 Coolant tubes 16 9N491 Coolant intake manifold 17 W701592 Bolt 18 NL443 Inter cooler hose 19 NL443 Inter cooler hose 20 W506404 Bolts 10 req d 21 6K755 Charge air cooler 22 6F066 Supercharger assembly 23 N605892 Bolt 24 9726 Accelerator cable bracket ...

Page 1391: ...art Number Description 1 N605904 Bolt 2 N620480 Nut 3 6A946 Cover 4 17K814 Alternator bracket assembly 5 N811268 Bolts 2 req d 6 8620 Accessory drive belt 7 N606543 Bolt 4 req d 8 6L266 Timing chain tensioner ...

Page 1392: ...ds 5 req d 25 6700 Crankshaft front seal 26 6316 Crankshaft pulley 27 N806165 Washer 28 W701512 Stud 29 8A528 Water pump pulley 30 N806282 Bolts 4 req d 31 N806177 Bolts 4 req d 32 8501 Water pump 33 N808102 Bolt 34 19A216 Belt idler pulley 35 N804178 Nut 36 N806300 Harness support bracket 37 N806300 Stud 38 N806155 Bolt 39 6C315 Crankshaft position sensor 40 N806155 Bolt 41 6B288 Camshaft positio...

Page 1393: ... and tube assembly Item Part Number Description 1 6083 Cylinder head gasket 2 Bolt 2 req d 3 Washer 2 req d 4 6255 Spacer 5 Secondary timing chain 2 req d 6 Screw and washer 7 6C271 Timing chain vibration damper ...

Page 1394: ... Camshaft 15 6B278 Camshaft bearing cap 2 req d 16 9448 Exhaust manifold gasket 17 9F485 EGR valve tube to manifold connector 18 W701706 Nut 8 req d 19 9431 Exhaust manifold 20 6C324 PCV tube 21 6A505 Valve cover 22 N808199 Bolt 20 req d 23 6766 Oil filler cap 24 12A366 Ignition coils 25 6P068 Ignition coil cover 26 N807309 Bolt 4 req d 27 6050 Cylinder head ...

Page 1395: ...lt 2 req d 2 6211 Connecting rod bearing 16 req d 3 6140 Piston pin retainer 16 req d 4 6135 Piston pin 8 req d 5 6110 Piston 8 req d 6 6159 Piston ring 8 req d 7 6159 Piston ring 8 req d part of 6100 8 6150 Piston ring 8 req d part of 6100 ...

Page 1396: ...cover 12 6051 Cylinder head gasket 13 W701706 Nut 8 req d 14 9430 Exhaust manifold 15 9448 Exhaust manifold gasket 16 W701681 Stud 8 req d 17 6049 Cylinder head 18 6C527 Spark plug gasket 8 req d 19 6200 Connecting rod 8 req d 20 6200 Connecting rod 8 req d 21 6161 Piston ring 8 req d ...

Page 1397: ...rt Number Description 1 8555 Water bypass tube 2 6750 Oil level indicator 3 6754 Oil level indicator tube 4 N806155 Bolt 5 6C358 Bolt 10 req d 6 6714 Oil bypass filter 7 6A642 Oil cooler 8 N806156 Bolt 4 req d ...

Page 1398: ...807959 Bolt 4 18663 Heater water hose 5 W500110 Bolt 2 req d 6 12A699 Knock sensor 2 req d 7 N807309 Bolt 2 req d 8 18696 Heater water hose 9 7120 Pilot bearing 10 6K318 Crankshaft rear retainer 11 N806155 Bolt 6 req d 12 6310 Crankshaft oil slinger 13 6375 Flywheel 14 N808139 Bolt 8 req d 15 7550 Clutch disc 16 7563 Clutch pressure plate 17 N808969 Bolt 6 req d 18 6701 Crankshaft rear oil seal ...

Page 1399: ...7 Dowel pin 2 req d Item Part Number Description 1 N806177 Bolt 4 req d 2 N806459 Dowel 4 req d 3 6A341 Thrust washer 4 6303 Crankshaft 5 6A339 Thrust bearing 6 6325 Main bearing cap 5 req d 7 6345 Bolt 10 req d ...

Page 1400: ...lt 16 req d 15 6622 Oil pump screen pickup and tube 16 N806155 Bolt 2 req d 17 N811280 Spacer 3 req d 18 6345 Bolt 6 req d 19 6C360 Main bearing cap adjusting screw 10 req d 20 6A338 Crankshaft main bearing 4 req d 21 N806201 Woodruff key 22 6621 Oil pump 23 N806183 Bolt 4 req d 24 6333 Crankshaft main bearing 25 8501 Water pump ...

Page 1401: ...G Engine Refer to Section 303 00 for basic mechanical concerns or refer to the Powertrain Control Emissions Diagnosis PC ED manual for driveability concerns SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1402: ... refer to Section 310 00 4 Disconnect the radiator upper hose radiator lower hose and the supercharger degas hose 5 Remove the supercharger belt For additional information refer to Section 303 05 6 Disconnect the coolant hose SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual Material Item Specification Motorcraft Premium Engine Coolant VC 4 A in Oregon VC 5 in Canada CXC 10 green c...

Page 1403: ...idle air control IAC valve electrical connectors 9 Disconnect the vacuum hose 10 Disconnect the fuel hose spring lock coupling For additional information refer to Section 310 00 11 Disconnect the accelerator controls Disconnect the accelerator cable If equipped disconnect the speed control cable 12 Remove the accelerator cable bracket bolts ...

Page 1404: ...fuel pulse damper exhaust gas recirculation EGR vacuum regulator solenoid supercharger bypass vacuum solenoid and the differential pressure feedback EGR system 15 Disconnect the vacuum hoses from the differential pressure feedback EGR system 16 Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid and the actuator ...

Page 1405: ...se damper and the EGR vacuum regulator solenoid 18 Disconnect the vacuum hose from the EGR valve 19 Disconnect the vacuum hoses at the back of the supercharger and position the vacuum harness aside 20 Remove the vacuum accessory bracket mounting nut ...

Page 1406: ...ing bolts and the vacuum accessory bracket 22 Disconnect the exhaust manifold to EGR valve tube 23 Disconnect the barometric pressure BARO sensor electrical connector 24 Disconnect the positive crankcase ventilation hose ...

Page 1407: ...olts and the intake manifold and the supercharger and fuel supply manifold as an assembly 27 NOTE Inspect the intake manifold gaskets and install new gaskets if necessary NOTE Install new bypass tube O rings and lubricate them using premium engine coolant To install reverse the removal procedure Tighten the intake manifold bolts in the sequence shown ...

Page 1408: ...l and bleed the engine cooling system For additional information refer to Section 303 03A in this section 29 Fill and bleed the supercharger cooling system For additional information refer to Section 303 03B ...

Page 1409: ...y For additional information refer to Section 412 03 4 Disconnect the throttle position TP sensor and the idle air control IAC valve electrical connectors 5 Disconnect the vacuum hose 6 Disconnect the fuel hose spring lock coupling For additional information refer to Section 310 00 SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual Material Item Specification Silicone Gasket and Sea...

Page 1410: ...ct the accelerator cable If equipped disconnect the speed control cable 8 Remove the accelerator cable bracket bolts 9 Release the clip and position the accelerator cable bracket and the cables aside 10 Remove the throttle body and spacer assembly ...

Page 1411: ...ealing surfaces 12 Inspect the valve cover spark plug hole gaskets Install new gaskets if necessary Make sure the gaskets are correctly seated on the valve cover 13 NOTE If the valve cover is not secured within four minutes the sealant must be removed and the sealing area cleaned with metal surface cleaner Allow to dry until there is no sign of wetness or four minutes whichever is longer Failure t...

Page 1412: ...14 To install reverse the removal procedure Tighten the valve cover bolts in the sequence shown ...

Page 1413: ......

Page 1414: ... and unclip the wiring harness from the stud 4 Unclip the wiring harness from the power steering bracket 5 Disconnect the electrical connectors from the fuel pulse damper EGR vacuum regulator solenoid supercharger bypass vacuum solenoid and the differential pressure feedback EGR system SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual Material Item Specification Silicone Gasket and...

Page 1415: ...tem 7 Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid and the actuator 8 Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid and position the vacuum harness aside 9 Remove the vacuum accessory bracket mounting nut ...

Page 1416: ...the vacuum accessory bracket 11 Disconnect the camshaft position CMP sensor electrical connector 12 Remove the fasteners and position the power steering reservoir aside 13 Remove the bolt and position the oil level indicator tube aside ...

Page 1417: ...crapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges which make leak paths Use a plastic scraping tool to remove all traces of old sealant Remove the valve cover Remove and discard the gasket clean and inspect the sealing surfaces ...

Page 1418: ...inutes the sealant must be removed and the sealing area cleaned with metal surface cleaner Allow to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure can result in future oil leakage Apply a bead of silicone gasket and sealant in two places where indicated 18 To install reverse the removal procedure Tighten the valve cover in the sequence sh...

Page 1419: ......

Page 1420: ...For additional information refer to Section 303 05 3 Remove the bolt 4 Using the special tool remove the crankshaft pulley SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Remover Crankshaft Vibration Damper 303 009 T58P 6316 D Installer Crankshaft Vibration Damper 303 102 T74P 6316 B Material Item Specification Silicone Gasket and Sealant F7AZ 19554 EA WSE M4G323 A...

Page 1421: ...o the Woodruff key slot on the crankshaft pulley 2 Using the special tool install the crankshaft pulley 3 Install the bolt and washer Tighten the bolt in four stages Stage 1 Tighten the bolt to 90 Nm 66 lb ft Stage 2 Loosen the bolt one full turn Stage 3 Tighten the bolt to 50 Nm 37 lb ft Stage 4 Tighten the bolt an additional 85 to 95 degrees ...

Page 1422: ...nstall the accessory drive belt For additional information refer to Section 303 05 5 Install the auxiliary crankshaft pulley For additional information refer to Crankshaft Pulley Auxiliary in this section ...

Page 1423: ...nformation refer to Section 303 03A 2 Remove the supercharger drive belt cover 3 Rotate the supercharger belt tensioner clockwise and remove the supercharger belt 4 Remove the coolant hose assembly bolt SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Locking Tool Flywheel 303 673 ...

Page 1424: ...on refer to Section 100 02 6 Remove the starter motor terminal cover 7 Disconnect the starter wiring 1 Remove the nut and disconnect the battery positive cable 2 Remove the nut and disconnect the starter solenoid wire 8 Remove the three bolts and the starter ...

Page 1425: ... Remove the bolts and the alternator support bracket 11 Remove the nut and position the wiring harness aside 12 Remove the stud and position the coolant hose assembly aside 13 Remove the auxiliary crankshaft pulley brace fasteners ...

Page 1426: ...14 NOTE The auxiliary crankshaft pulley is left hand threaded Remove the auxiliary crankshaft pulley and brace assembly 15 To install reverse the removal procedure ...

Page 1427: ...seal SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Installer Front Cover Oil Seal 303 335 T88T 6701 A Remover Crankshaft Front Oil Seal 303 107 T74P 6700 A Installer Crankshaft Front Oil Seal 303 635 Installer Crankshaft Vibration Damper 303 102 T74P 6316 B Material Item Specification SAE 5W 20 Premium Synthetic Blend Engine Oil XO 5W20 QSP or equivalent WSS M2C1...

Page 1428: ...ean engine oil 2 Using the special tool install the crankshaft front seal 3 Install the crankshaft pulley For additional information refer to Crankshaft Pulley in this section 4 Install the auxiliary crankshaft pulley For additional information refer to Crankshaft Pulley Auxiliary in this section ...

Page 1429: ......

Page 1430: ... the fourth bolt hidden below the power steering tube and position the power steering pump aside 4 Remove the A C muffler bracket nut 5 Remove the bolts and position the A C compressor aside SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual Material Item Specification Metal Surface Cleaner F4AZ 19A536 RA or equivalent WSE M5B392 A Silicone Gasket and Sealant F7AZ 19554 EA or equiva...

Page 1431: ...6 Disconnect the crankshaft position sensor 7 Remove the four front bolts 8 Disconnect the generator electrical connector 9 Remove the generator B terminal nut and detach the B cable ...

Page 1432: ...itional information refer to Section 303 03A and Section 303 03B 13 Lower the vehicle 14 Remove the coolant bypass tube For additional information refer to Section 303 03A 15 Remove the left and right valve covers For additional information refer to Valve Cover LH and Valve Cover RH in this section 16 Disconnect the supercharger coolant hose ...

Page 1433: ...ing bolt 18 Disconnect the supercharger coolant hoses and remove the supercharger hose and tube assembly 19 Disconnect the camshaft position CMP sensor electrical connector 20 Unclip the wiring harness from the power steering bracket ...

Page 1434: ...2 Disconnect the power steering hoses and drain the power steering fluid into a suitable container 23 Remove the fasteners and the power steering reservoir 24 Remove the nut and the position the power steering hose aside ...

Page 1435: ... Remove the fasteners and the supercharger belt idler support bracket assembly 26 Remove the wiring harness bracket 27 Remove the water pump pulley 28 Remove the bolts the studs and the engine front cover ...

Page 1436: ...inspect the sealing surfaces Installation 1 NOTE If the valve cover is not secured within four minutes the sealant must be removed and the sealing area cleaned with metal surface cleaner Allow to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure can result in future oil leakage Apply silicone gasket and sealant in the locations shown 2 Insta...

Page 1437: ...d Hex Shldr Pilot M8 x 1 25 x 1 25 x 91 1 7 N806300 Stud Hex Shldr Pilot M8 x 1 25 x 1 25 x 91 1 8 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 9 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 10 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 11 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 12 W706560 Stud Hex Head Pilot M8 x 1 25 x 65 M8 x 1 25 x 16 13 N806300 Stud Hex Shldr Pilot ...

Page 1438: ... wiring harness bracket and the nut 5 Install the supercharger belt idler support bracket assembly and fasteners 6 Install the power steering hose bracket nut 7 Install the power steering reservoir and the fasteners ...

Page 1439: ...8 Connect the power steering hoses 9 Install the power steering hose nut 10 Attach the wiring harness to the power steering bracket 11 Connect the camshaft position CMP sensor electrical connector ...

Page 1440: ...ll the coolant hose mounting bolt 14 Connect the supercharger coolant hose 15 Install the left and right valve covers For additional information refer to Valve Cover LH and Valve Cover RH in this section 16 Install the coolant bypass tube For additional information refer to Section 303 03A ...

Page 1441: ...aise the vehicle 18 Install the generator support bracket 19 Install the generator and the bolts 20 Attach the B cable and install the generator B terminal nut 21 Connect the generator electrical connector ...

Page 1442: ...tage 1 Tighten to 2 Nm 18 lb in Stage 2 Tighten to 20 Nm 15 lb ft Stage 3 Tighten an additional 60 degrees 23 Connect the crankshaft position sensor electrical connector 24 Position the A C compressor and install the bolts 25 Install the A C muffler bracket nut ...

Page 1443: ... Oil Filter Adapter in this section 28 Install the crankshaft front seal For additional information refer to Crankshaft Front Seal in this section 29 Fill and bleed the engine coolant and the supercharger coolant For additional information refer to Section 303 03A and Section 303 03B 30 Fill the crankcase with clean engine oil ...

Page 1444: ......

Page 1445: ... refer to Engine Front Cover in this section 2 Remove the crankshaft sensor ring from the crankshaft 3 CAUTION Unless otherwise instructed at no time when the timing chains 6268 are removed and the cylinder heads 6049 are installed is the crankshaft 6303 or the camshaft 6250 to be rotated Severe piston 6108 and valve damage will occur Using the special tool position the crankshaft as shown SECTION...

Page 1446: ...ove the two bolts the timing chain tensioner 6L266 and tensioner arm 6L253 6 CAUTION Unless otherwise instructed at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the camshaft to be rotated Severe piston and valve damage will occur Remove the LH and RH timing chains and the crankshaft sprocket 6306 Remove the special tool from the crankshaft Re...

Page 1447: ...s and the timing chain guides 6K297 Installation 1 CAUTION Timing chain procedures must be followed exactly or damage to the pistons or valves will result Compress the tensioner plunger using a soft jawed vise 2 Install a retaining clip on the tensioner to hold the plunger in during installation Remove the tensioner from the vise ...

Page 1448: ...s 4 Install the timing chain guides 5 Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o clock position Rotate the RH camshaft timing sprocket until the timing mark is approximately in the 11 o clock position 6 CAUTION Unless otherwise instructed at no time when the timing chains are ...

Page 1449: ...evere piston or valve damage will occur Using the special tool position the crankshaft 7 Remove the special tool 8 Install the crankshaft sprocket with the flange facing forward 9 NOTE LH timing chain shown RH similar Install the LH timing chain onto the crankshaft sprocket aligning the one copper link on the timing chain 6268 with the slot on the crankshaft sprocket 10 Verify the camshaft sprocke...

Page 1450: ...d tensioners and install the bolts 12 Remove the retaining clips from the timing chain tensioners 13 Position the crankshaft sensor ring on the crankshaft 14 Install the engine front cover For additional information refer to Engine Front Cover in this section ...

Page 1451: ......

Page 1452: ...rmation refer to Camshaft Roller Follower in this section 2 Remove the 16 hydraulic lash adjusters 3 Inspect the roller followers For additional information refer to Section 303 00 Installation 1 To install reverse the removal procedure SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1453: ...3 Using the special tool compress the intake valve spring and remove the roller follower 4 Using the special tool compress the exhaust valve spring and remove the roller follower 5 Repeat Steps 2 3 and 4 to remove all the necessary roller followers Inspect roller finger followers and camshafts For additional information refer to Section 303 00 6 To install reverse the removal procedure SECTION 303...

Page 1454: ......

Page 1455: ... side For additional information refer to Timing Drive Components in this section 3 Install the special tool 4 Remove the exhaust camshaft sprocket 6250 and the intake camshaft bolt washer and spacer SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Holding Tool Camshaft 303 446 T93P 6256 AHR Material Item Specification Super Premium SAE 5W 20 Engine Oil XO 5W20 QSP ...

Page 1456: ...5 Remove the special tool 6 Compress the tensioner 6L266 and install a lock pin 7 Remove the timing chain the sprocket and intake camshaft sprocket spacer 8 NOTE LH shown RH similar Remove the bolts ...

Page 1457: ... exhaust are longer and must be returned to the same location or engine damage may occur NOTE Identify the camshaft to cylinder head location Caps are not interchangeable Remove the bolts and the camshaft bearing cap assemblies 10 Remove the camshafts 6250 ...

Page 1458: ...Installation 1 NOTE LH shown RH similar Install the camshafts Lubricate the camshafts with clean engine oil 2 Install the camshaft bearing cap assemblies and tighten the bolts in the sequence shown ...

Page 1459: ...3 Install the bolts 4 CAUTION Timing marks must be at 12 o clock and indexed at 6 o clock Install the camshaft sprockets and the chain as an assembly 5 Remove the lockpin from the chain tensioner ...

Page 1460: ... the camshaft spacer washer and bolt and hand tighten the bolt 8 Install the camshaft sprocket washer and bolt and hand tighten the bolt 9 Tighten the bolts in two stages Stage 1 Tighten to 40 Nm 30 lb ft Tighten an additional 90 degrees ...

Page 1461: ...ng chain for the left side or both timing chains for the right side For additional information refer to Timing Drive Components in this section 12 Install the roller followers For additional information refer to Camshaft Roller Follower in this section ...

Page 1462: ...verter Y pipe For additional information refer to Section 309 00 4 Remove the starter For additional information refer to Section 303 06 5 Remove the exhaust manifold 1 Remove the nuts 2 Remove the exhaust manifold 3 Remove and discard the gasket 6 To install reverse the removal procedure Use a new exhaust manifold gasket Tighten the exhaust manifold nuts in the sequence shown SECTION 303 01C Engi...

Page 1463: ......

Page 1464: ...n refer to Section 414 01 3 Raise the vehicle For additional information refer to Section 100 02 4 Remove the dual converter Y pipe For additional information refer to Section 309 00 5 Remove and discard the pinch bolt 6 Separate the steering coupler 7 Disconnect the exhaust gas recirculation EGR tube at the exhaust manifold SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1465: ...e the nuts 2 Remove the exhaust manifold 3 Remove and discard the gasket 9 Remove the oil level indicator tube 10 Remove and discard the exhaust manifold gasket 11 To install reverse the removal procedure Use a new exhaust manifold gasket ...

Page 1466: ......

Page 1467: ...lower radiator hose 3 Raise the vehicle For additional information refer to Section 100 02 4 Drain the engine oil 5 Remove the oil cooler 1 Remove the oil bypass filter 2 Remove the insert and the oil cooler 3 Inspect the O ring and clean the sealing surface 6 Clean and inspect the oil cooler SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1468: ...stall a new cooler 7 Remove the oil filter adapter 1 Remove the bolts 2 Remove the oil filter adapter 3 Remove the gasket 8 Clean and inspect the oil filter adapter Flush the oil filter adapter with parts cleaner If metal particles are present in the adapter install a new adapter 9 To install reverse the removal procedure ...

Page 1469: ......

Page 1470: ...move the LH exhaust manifold 9430 For additional information refer to Exhaust Manifold LH in this section 3 Remove the bolt 4 Remove the oil level indicator tube 6754 Installation 1 To install follow the removal procedure in reverse SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1471: ......

Page 1472: ...ulator to compressor 4 6L For additional information refer to Section 412 03 6 Remove the A C line For additional information refer to Section 412 03 SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Compressor Coil Spring 204 D001 D78P 5310 A Lifting Bracket Engine 303 D088 D93P 6001 A2 3 Bar Engine Support Kit 303 F072 Material Item Specification Metal Surface Clea...

Page 1473: ...he special tools 8 Install the special tool 9 Raise the vehicle on a hoist For additional information refer to Section 100 02 10 Remove the two nuts 11 Lower the vehicle 12 Using the special tool raise the engine ...

Page 1474: ...aise the vehicle on a hoist 14 Remove the oil pan drain plug 6730 and drain the engine oil 15 Using the special tool compress the front coil springs 5310 16 Position a safety stand 17 Remove the four bolts ...

Page 1475: ...E Do not completely remove the bolts Loosen the bolts 19 Lower the front sub frame 5C145 20 Remove the sub frame brace 21 Remove the starter wiring harness nuts and position the wiring harness out of the way ...

Page 1476: ... and inspect the mating surfaces 2 NOTE If the oil pan is not secured within four minutes the sealant must be removed and the sealing area cleaned with metal surface cleaner Allow to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure may result in future oil leakage Apply silicone gasket and sealant at the engine front cover to cylinder block...

Page 1477: ...one gasket and sealant at the rear oil seal retainer to cylinder block sealing surface 4 Install the oil pan and gasket and loosely install the bolts 5 Tighten the bolts in the sequence shown in three stages Stage 1 Tighten to 2 Nm 18 lb in Stage 2 Tighten to 20 Nm 15 lb ft Stage 3 Tighten an additional 60 degrees ...

Page 1478: ...6 Install the oil pan drain plug 7 Position the starter wiring harness and install the wiring harness nuts 8 Install the sub frame brace ...

Page 1479: ...9 Raise the front sub frame into position 10 Install the two bolts 11 Install the two bolts 12 Install the four bolts ...

Page 1480: ...safety stand aside 14 Release the tension from the front coil springs and remove the special tool 15 Raise the vehicle 16 Using the special tool lower the engine and remove the special tool 17 Remove the special tools ...

Page 1481: ...l information refer to Section 412 03 23 Install the manifold and tube assembly accumulator to compressor 4 6L For additional information refer to Section 412 03 24 Install the radiator sight shield 25 Install the air cleaner outlet tube For additional information refer to Section 303 12 26 Install the battery ground cable For additional information refer to Section 414 01 27 Start the engine and ...

Page 1482: ......

Page 1483: ... Remove the clutch components For additional information refer to Section 308 01 2 Remove the bolts and the flywheel Installation 1 To install reverse the removal procedure SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1484: ...l 303 518 T95P 6701 DH Remover Crankshaft Rear Oil Seal 303 519 T95P 6701 EH Installer Crankshaft Rear Oil Seal 303 516 T95P 6701 BH Remover Crankshaft Rear Oil Slinger 303 514 T95P 6701 AH Installer Crankshaft Rear Oil Slinger 303 517 T95P 6701 CH Slide Hammer 100 001 T50T 100 A Material Item Specification Super Premium SAE 5W 20 Engine Oil XO 5W20 QSP or equivalent WSS M2C153 H ...

Page 1485: ...special tools remove the crankshaft oil slinger 3 Using the special tools remove the crankshaft rear oil seal 6701 Installation 1 Using the special tools install the crankshaft rear oil seal Lubricate the oil seal using clean engine oil 2 Using the special tool install the crankshaft oil slinger ...

Page 1486: ...3 Install the flywheel For additional information refer to Flywheel in this section ...

Page 1487: ...stall the special tool 3 Raise the vehicle For additional information refer to Section 100 02 4 Remove the two nuts SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Lifting Bracket Engine 303 D088 D93P 6001 A2 3 Bar Engine Support Kit 303 F072 ...

Page 1488: ...5 Lower the vehicle 6 Using the special tool raise the engine 7 Raise the vehicle 8 Remove the engine mount Installation 1 To install reverse the removal procedure ...

Page 1489: ......

Page 1490: ...stall the special tool 3 Raise the vehicle For additional information refer to Section 100 02 4 Remove the two nuts SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Lifting Bracket Engine 303 D088 D93P 6001 A2 3 Bar Engine Support Kit 303 F072 ...

Page 1491: ...5 Lower the vehicle 6 Using the special tool raise the engine 7 Raise the vehicle on a hoist 8 Remove the engine mount Installation 1 To install follow the removal procedure in reverse ...

Page 1492: ......

Page 1493: ...percharger cooling system For additional information refer to Section 303 03B 5 Recover the A C system refrigerant For additional information refer to Section 412 00 6 Remove the hood to body ground strap 7 NOTE Mark the hood hinge locations to aid in hood installation SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Lifting Bracket Engine 303 D087 D93P 6001 A1 Lift...

Page 1494: ...move the four nuts and the hood 8 Disconnect the intake air temperature IAT sensor 9 Disconnect the breather hose 10 Disconnect the vacuum hose 11 Loosen the clamps and remove the air cleaner outlet pipe ...

Page 1495: ... and the idle air control IAC valve electrical connectors 13 Disconnect the vacuum hose 14 Disconnect the A C pressure switch electrical connector 15 Disconnect the fuel tube spring lock coupling For additional information refer to Section 310 00 ...

Page 1496: ...celerator cable If equipped disconnect the speed control cable 17 Remove the accelerator cable bracket bolts 18 Release the clip and position the accelerator cable bracket and the cables aside 19 Remove the four nuts and the throttle body and spacer assembly ...

Page 1497: ...nd the 42 pin connectors 21 Disconnect the vacuum hoses 22 Separate the wiring harness from the dash panel 23 Disconnect the heater hoses 24 Disconnect the radiator upper hose radiator lower hose and the supercharger degas hose ...

Page 1498: ...25 Disconnect the A C suction tube from the accumulator 26 Disconnect and remove the A C suction tube 27 Disconnect the A C tube 28 Remove the nuts and disconnect the A C tubes ...

Page 1499: ...29 Remove the nut and the A C manifold tube 30 Remove the hood prop 31 Remove the push pins and the radiator sight shield 32 Disconnect the radiator vent hose from the degas bottle ...

Page 1500: ...33 Remove the degas bottle return hose 34 Remove the nuts and the degas bottle 35 Disconnect the power steering hoses 36 Remove the fasteners and the power steering reservoir and bracket ...

Page 1501: ...37 Remove the power steering hose bracket 38 Disconnect the supercharger degas hose 39 Remove the bolts and the supercharger degas bottle 40 Disconnect the radiator lower hose ...

Page 1502: ... the supercharger coolant hoses 42 Disconnect the cooling fan electrical connector 43 Remove the LH cooling fan shroud bolt 44 Remove the RH cooling fan shroud bolt and remove the fan motor and shroud as an assembly ...

Page 1503: ...45 Disconnect the power steering hose 46 Remove the power steering bracket bolt 47 Remove the power steering hose from the grommet 48 Remove the bolts and the battery tray ...

Page 1504: ... to Section 308 01 51 Remove the transmission wiring harness 1 Remove the RH oxygen sensor connector from the bracket 2 Disconnect the transmission wiring connector and remove the harness 52 NOTE LH is shown RH is similar Remove the right and left exhaust manifold flange nuts and position the exhaust manifold aside 53 Drain the engine oil Install the drain plug when finished ...

Page 1505: ...ove the nut and the wiring harness bracket 55 Disconnect the oil pressure sender electrical connector 56 Disconnect the generator electrical connector 57 Remove the generator B nut and disconnect the B cable ...

Page 1506: ...58 Remove the nut and the engine ground cable 59 Disconnect the hose from the oil filter adapter 60 Disconnect and remove the lower hose from the radiator 61 Remove the ground strap bolt ...

Page 1507: ...62 Remove the degas bottle support bracket 63 NOTE RH side shown LH side similar Remove the two engine mount nuts 64 Lower the vehicle 65 Remove the two screws and position the clutch cable aside ...

Page 1508: ...own LH is similar Remove the right and left ignition coil covers 67 Install the special tool 68 Install the special tool 69 Attach the special tool to a floor crane and the engine and remove the engine from the vehicle ...

Page 1509: ......

Page 1510: ...over Crankshaft Vibration Damper 303 009 T58P 6316 D Holding Tool Crankshaft 303 448 T93P 6303 A Installer Connecting Rod 303 442 T93P 6136 A Remover Crankshaft Rear Oil Seal 303 519 T95P 6701 EH Remover Crankshaft Rear Oil Slinger 303 514 T95P 6701 AH Compressor Valve Spring Intake 303 452 T93P 6565 AR Compressor Valve Spring Exhaust ...

Page 1511: ...1 Remove the bolts and the flywheel 2 Using the special tool remove the rear oil slinger 3 Using the special tool remove the rear main seal 303 567 T97P 6565 AH Remover Crankshaft Front Oil Seal 303 107 T74P 6700 A ...

Page 1512: ...on a workstand 6 Remove the special tools 7 Remove the drain plug and drain the engine coolant 8 Disconnect the electrical connectors from the fuel pulse damper exhaust gas recirculation EGR vacuum regulator solenoid supercharger bypass vacuum solenoid and the differential ...

Page 1513: ...rential pressure feedback EGR system 10 Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid and the actuator 11 Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid 12 Disconnect the vacuum hose from the EGR valve ...

Page 1514: ... at the back of the supercharger and remove the vacuum harness 14 Remove the vacuum accessory bracket mounting nut 15 Remove the mounting bolts and the vacuum accessory bracket 16 Remove the positive crankcase ventilation PCV valve ...

Page 1515: ...ove the PCV hose 18 Disconnect the barometric pressure BARO sensor electrical connector 19 Disconnect the EGR tube from the exhaust manifold 20 NOTE Discard the EGR valve gasket Remove the EGR valve and tube as an assembly ...

Page 1516: ...ect the camshaft position CMP sensor electrical connector 23 Disconnect the engine coolant temperature ECT sensor electrical connector and unclip the harness from the stud 24 NOTE LH is shown RH is similar Disconnect the two radio ignition interference capacitor electrical connectors ...

Page 1517: ...e the fuel charging wiring harness bracket bolt 26 Disconnect the crankshaft position CKP sensor electrical connector 27 Disconnect the A C compressor electrical connector 28 Unclip the harness from the bracket ...

Page 1518: ...cket 30 Disconnect the electrical connectors and remove the RH ignition coils 31 Disconnect the eight fuel injectors 32 Separate the harness from the fuel supply manifold studs in four places and remove the fuel charging wiring harness ...

Page 1519: ...undamaged Remove the ten bolts and the intake manifold and the supercharger and fuel supply manifold as an assembly 34 Remove the bolts and the heater water outlet tube 35 Remove the bolts and the heater water inlet tube 36 NOTE LH is shown RH is similar ...

Page 1520: ...use metal scrapers wire brushes power abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges which make leak paths Use a plastic scraping tool to remove all traces of old sealant NOTE LH is shown RH is similar Remove the fasteners and the LH and RH valve covers Remove and discard the gasket clean and inspect the sealing surfaces ...

Page 1521: ...r support bracket assembly 41 Remove the accessory drive belt 42 Remove the bolts and belt idler bracket 43 Remove the bolts and the water pump pulley 44 Remove the water pump from the cylinder block Inspect and clean the sealing surfaces ...

Page 1522: ...45 Remove the bolt 46 Using the special tool remove the crankshaft pulley 47 Using the special tools remove the crankshaft front seal 48 Remove the bolts and the A C compressor ...

Page 1523: ...s similar Remove the exhaust manifold 1 Remove the nuts 2 Remove the exhaust manifold 3 Remove and discard the exhaust manifold gasket 50 Remove the bolts and the generator 51 Remove the bolts and the generator support bracket ...

Page 1524: ...ean and inspect the oil filter adapter and the oil cooler Plug the oil cooler coolant lines Flush the adapter and cooler with parts cleaner If metal particles are present install a new oil filter adapter and oil cooler 55 Remove the power steering pressure hose 56 Remove the bolts and the power steering pump ...

Page 1525: ... four bolts 58 Remove the bolts the studs and the engine front cover 59 NOTE The oil pan gasket is reusable if not damaged Inspect the gasket and install new if necessary Remove the bolts the oil pan and the gasket ...

Page 1526: ...NOTE Make sure the base circle of the camshaft is facing the roller follower being removed Using the special tool remove the 32 roller followers 62 Remove the bolts and the RH and LH timing chain tensioners 63 Remove the RH and LH timing chain tensioner arms ...

Page 1527: ...kshaft sprocket 65 Remove the bolts and the RH and LH timing chain guides 66 NOTE Cylinder head bolts are not to be reused Discard the bolts Remove the bolts and the RH and LH cylinder heads 67 Remove the bolts and the oil pump screen and pickup tube 6622 ...

Page 1528: ...Remove the oil pump screen and pickup tube spacer 69 Remove the spacers and the windage tray 70 NOTE RH is shown LH is similar Remove the RH and LH engine mounts 71 Remove the bolts and remove the oil pump ...

Page 1529: ...cylinder walls or crankshaft journals with the connecting rod NOTE Before removing pistons inspect the top of the cylinder bores If necessary remove the ridge or carbon deposits from each cylinder using a cylinder ridge reamer Follow manufacturer s instructions Using the special tool push pistons number 1 and 6 through the top of the cylinder block 74 To remove pistons number 3 and 5 4 and 7 2 and...

Page 1530: ...76 Remove and discard the bolts 77 Remove the main bearing caps and the crankshaft lower main bearings from the cylinder block ...

Page 1531: ...78 Remove the crankshaft the crankshaft thrust washer and the crankshaft upper main bearings from the cylinder block ...

Page 1532: ......

Page 1533: ...303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Compressor Valve Spring Exhaust Side 303 567 T97P 6565 AH Compressor Valve Spring Intake Side 303 452 T93P 6565 AR Holding Tool Camshaft 303 446 T93P 6256 AHR Air Operated Valve Spring Holder 134 R0207 or equivalent Installer Valve Stem Oil Seal 303 383 T91P 6571 A Material Item Specification Super Premium SAE 5W 20 Engine Oi...

Page 1534: ...ust be re installed into the same positions Install the special tool 2 Remove the exhaust camshaft sprocket and the intake camshaft bolt washer and spacer 3 Compress the tensioner 6L266 and install a lock pin 4 Remove the special tool ...

Page 1535: ... RH tensioner is similar Remove the tensioner 7 Remove the roller followers on the base circle 1 Install the special tool on the valve spring 2 Compress the tool and remove the roller follower 8 Repeat the previous step for the remaining roller followers 9 Remove the hydraulic lash adjusters ...

Page 1536: ...using damage to the cylinder head Install the air operated spring compressor on the cylinder head 11 Compress the valve spring compressor and remove the key from the valves 12 Remove the intake valves and the valve springs 1 Release the pressure and remove the valve spring compressor 2 Remove the intake valves and the valve springs from the cylinder head ...

Page 1537: ...s on the outer cam bearing cap exhaust are longer and must be returned to the same location or engine damage may occur NOTE Identify the camshaft to cylinder head location Caps are not interchangeable Remove the bolts and the camshaft bearing cap assemblies ...

Page 1538: ...e valves and the valve springs 3 CAUTION Make sure the tool is seated correctly on the valve spring Apply a small amount of air at a time This will prevent the tool from shifting and causing damage to the cylinder head Install the air operated spring compressor on the cylinder head ...

Page 1539: ...s the valve spring compressor and install the key on the valves 5 NOTE LH is shown RH is similar Install the camshafts Lubricate the camshafts with clean engine oil 6 Install the camshaft bearing cap assemblies ...

Page 1540: ...nstall the roller followers 1 Install the special tool on the valve spring 2 Compress the spring and install the roller follower 9 Repeat the previous step for the remaining roller followers 10 NOTE LH tensioner is shown RH tensioner is similar ...

Page 1541: ...AUTION Timing marks must be at 12 o clock and indexed at 6 o clock Install the camshaft sprockets and the chain as an assembly 12 Install the special tool 13 Install the camshaft spacer washer and bolt and hand tighten the bolt ...

Page 1542: ...stall the camshaft sprocket washer and bolt and hand tighten the bolt 15 Tighten the bolts in two stages Stage 1 Tighten to 40 Nm 30 lb ft Stage 2 Tighten and additional 90 degrees 16 Remove the special tool ...

Page 1543: ......

Page 1544: ... 2 Remove the piston pin 6135 from the piston 6108 and connecting rod assembly 3 Remove the connecting rod 6200 from the piston SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual Material Item Specification Super Premium SAE 5W 20 Motor Oil XO 5W20 QSP WSS M2C153 H ...

Page 1545: ...Section 303 00 Assembly 1 NOTE Connecting rod must be installed into piston with identification markings toward front Position the connecting rod in the piston 2 Lubricate the piston pin and pin bore with clean engine oil 3 Install the piston pin in the piston and connecting rod assembly ...

Page 1546: ...4 Install the piston pin retaining clips in the piston ...

Page 1547: ...embly 1 Disconnect and remove the PCV hoses 2 Remove the coolant supply and return manifold 3 Remove the coolant supply and return tubes and seals 4 Remove the bolts the supercharger and the charge air cooler CAC assembly SECTION 303 01C Engine Cobra 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1548: ...hten the supercharger and CAC cooler assembly to lower intake manifold bolts in the sequence shown in two stages 1 Stage 1 Tighten to 2 Nm 18 lb in 2 Stage 2 Tighten to 25 Nm 18 lb ft 8 Tighten the coolant supply and return manifold in two stages 1 Stage 1 Tighten to 10 Nm 89 lb ft 2 Stage 2 Tighten an additional 90 degrees ...

Page 1549: ......

Page 1550: ...kshaft Vibration Damper 303 102 T74P 6316 B Installer Front Cover Oil Seal 303 335 T88T 6701 A Installer Crankshaft Front Oil Seal 303 635 Installer Crankshaft Rear Oil Seal 303 518 T95P 6701 DH Installer Crankshaft Rear Oil Slinger 303 517 T95P 6701 CH Compressor Valve Spring Intake 303 452 T93P 6565 AR Compressor Valve Spring Exhaust 303 567 T97P 6565 AH ...

Page 1551: ...ton Ring 303 D032 D81L 6002 C or equivalent Holding Tool Crankshaft 303 448 T93P 6303 A Material Item Specification Metal Surface Cleaner F4AZ 19A536 RA or equivalent WSE M5B392 A Silicone Gasket and Sealant F7AZ 19554 EA or equivalent WSE M4G323 A4 SAE 5W 20 Premium Synthetic Blend Engine Oil XO 5W20 QSP or equivalent WSS M2C153 H Motorcraft Premium Engine Coolant VC 4 A in Canada CXC 10 in Orego...

Page 1552: ...rst letter of the crankshaft main bearing code Read down the column below the engine block main bearing code letter and across the row next to the crankshaft main bearing code letter until the two intersect This is the required bearing grade for the number one crankshaft main bearing As an example if the engine block code letter is F and the crankshaft code letter is D the correct bearing grade fo...

Page 1553: ... and the Bearing Select Fit Chart Oversize Bearings to determine the required bearing grade for each main bearing 5 Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil 6 Install the crankshaft onto the upper main bearings ...

Page 1554: ...aring caps NOTE Install the thrust bearing to the rear main bearing cap and lubricate it with clean engine oil NOTE Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil Apply forward force to the crankshaft so that the crankshaft thrust face is against the No 5 bulkhead With the crankshaft in this position locate the No 5 main bearing cap o...

Page 1555: ... the sequence shown in two stages Stage 1 Tighten to 40 Nm 30 lb ft Stage 2 Tighten an additional 90 degrees 10 Tighten the jack screws against the cylinder block in the sequence shown in two stages Stage 1 Tighten to 5 Nm 44 lb in Stage 2 Tighten to 10 Nm 89 lb in ...

Page 1556: ...he sequence shown 12 Check the crankshaft end play For additional information refer to Section 303 00 13 CAUTION Do not scratch the cylinder walls or crankshaft journals with the connecting rod NOTE Make sure that the piston arrow is facing forward ...

Page 1557: ...t journals with the connecting rod NOTE Make sure the crankshaft is at top dead center TDC Using the special tool install the connecting rod assemblies 15 NOTE The rod bearing cap bolts are torque to yield Install new bolts each time they are serviced Install the connecting rod bearing caps and bolts and tighten in three stages Stage 1 Tighten to 25 Nm 18 lb ft Stage 2 Tighten to 45 Nm 33 lb ft St...

Page 1558: ...information refer to Section 303 00 17 Install the windage tray 18 Install and tighten the oil pump screen spacer 19 Position the oil pump tighten the bolts in the sequence shown 20 NOTE Install a new O ring if necessary Install the oil pump screen cover and tube ...

Page 1559: ...ds and tighten the bolts in six stages in the sequence shown Stage 1 Tighten to 40 Nm 30 lb ft Stage 2 Tighten an additional 90 degrees Stage 3 Loosen the bolts a minimum of one full turn Stage 4 Tighten to 40 Nm 30 lb ft Stage 5 Tighten an additional 90 degrees Stage 6 Tighten an additional 90 degrees 23 CAUTION Timing chain procedures must be followed exactly or damage to valves and pistons will...

Page 1560: ...ining clip on the tensioner to hold the plunger in during installation 25 Remove the tensioner from the vise 26 If the copper links are not visible mark two links on one end and one link on the other end and use as timing marks 27 Install the timing chain guides ...

Page 1561: ... position the camshafts 1 Rotate the LH camshaft until the timing mark is approximately at 12 o clock 2 Rotate the RH camshaft until the timing mark is approximately at 11 o clock 29 Install the special tool ...

Page 1562: ...otate the crankshaft counterclockwise only Do not rotate past position shown or severe piston and or valve damage will occur Using the special tool position the crankshaft Remove the special tool 31 Install the crankshaft sprocket with the flange facing forward 32 Position the LH inner timing chain onto the crankshaft sprocket aligning the one copper link on the timing chain with the slot on the c...

Page 1563: ...h the timing marks on the sprocket 34 NOTE The LH timing chain tensioner arm has a bump near the dowel hole for identification Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner 35 Remove the retaining clip from the LH timing chain tensioner ...

Page 1564: ...arks on the sprocket 37 Install the RH timing chain on the camshaft sprocket aligning the copper marked link with the timing marks on the sprocket 38 Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner 39 Remove the retaining clip from the RH timing chain tensioner ...

Page 1565: ...s on the crankshaft sprockets and the camshaft sprockets 41 Remove the special tool 42 NOTE Make sure the base circle of the camshaft is facing the roller follower being installed Using the special tool install the 32 roller followers 43 Position the crankshaft sensor ring on the crankshaft ...

Page 1566: ...itional 60 degrees 46 NOTE If the engine front cover is not secured within four minutes the sealant must be removed and the sealing area cleaned with metal surface cleaner Allow to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure can result in future oil leakage Apply silicone gasket and sealant in the locations shown ...

Page 1567: ... x 1 25 x 53 4 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 5 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 6 N806300 Stud Hex Shldr Pilot M8 x 1 25 x 1 25 x 91 1 7 N806300 Stud Hex Shldr Pilot M8 x 1 25 x 1 25 x 91 1 8 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 9 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 10 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 11 N806177 Bolt ...

Page 1568: ...tage 3 Tighten an additional 60 degrees 49 Install the power steering pump and the bolts 50 Install the power steering hose 51 Install a new gasket and the oil filter adapter 13 N806300 Stud Hex Shldr Pilot M8 x 1 25 x 1 25 x 91 1 14 N806300 Stud Hex Shldr Pilot M8 x 1 25 x 1 25 x 91 1 15 N806300 Stud Hex Shldr Pilot M8 x 1 25 x 1 25 x 91 1 ...

Page 1569: ...he oil cooler 53 Install the generator support bracket 54 Install the generator 55 NOTE RH is shown LH is similar Use new gaskets when installing the exhaust manifolds Install the exhaust manifolds Tighten the nuts in the sequence shown ...

Page 1570: ... to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure can result in future oil leakage Apply silicone gasket and sealant in the locations shown 57 NOTE RH is shown LH is similar Inspect and install new O ring seals if necessary Install the valve covers and tighten the bolts in the sequence shown ...

Page 1571: ...within four minutes the sealant must be removed and the sealing area cleaned with metal surface cleaner Allow to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure can result in future oil leakage Apply silicone gasket and sealant to the Woodruff key on the crankshaft pulley 61 Using the special tool install the crankshaft pulley ...

Page 1572: ...ge 1 Tighten to 90 Nm 66 lb ft Stage 2 Loosen the bolt one full turn Stage 3 Tighten to 50 Nm 37 lb ft Stage 4 Tighten an additional 90 degrees 63 NOTE Lubricate the O ring seal with clean engine coolant Install the water pump 64 Install the water pump pulley and the bolts ...

Page 1573: ...er support bracket assembly 66 NOTE Lubricate the O rings with clean engine coolant NOTE LH is shown RH is similar Install the coolant bypass tube and mounting bolts 67 NOTE LH is shown RH is similar Install the coolant bypass tube studs ...

Page 1574: ... rings with clean engine coolant Install the heater water outlet tube and the mounting bolts 70 NOTE Inspect the intake manifold gaskets and install new gaskets if necessary Install the intake manifold supercharger and fuel supply manifold as an assembly and tighten the bolts to 10 Nm 89 lb in in the sequence shown ...

Page 1575: ...attach it to the four fuel supply manifold studs 72 Connect the eight fuel injector electrical connectors 73 NOTE RH is shown LH is similar Install the RH and LH ignition coils and connect the electrical connectors 74 Install the harness support bracket ...

Page 1576: ...lip the harness to the bracket 76 Connect the A C compressor electrical connector 77 Connect the crankshaft position CKP sensor electrical connector 78 Install the fuel charging wiring harness bracket bolt ...

Page 1577: ...radio ignition interference capacitors 80 NOTE LH is shown RH is similar Connect the two radio ignition interference capacitor electrical connectors 81 Connect the engine coolant temperature ECT sensor electrical connector and attach the harness to the stud ...

Page 1578: ...ical connector 83 Install the power steering reservoir and mounting bolts 84 Attach the wiring harness to the power steering support bracket 85 NOTE Install a new exhaust gas recirculation EGR valve gasket Install the EGR valve and tube as an assembly ...

Page 1579: ...aust manifold 87 Connect the barometric pressure BARO sensor electrical connector 88 Install and connect the positive crankcase ventilation PCV hose 89 Install the PCV valve 90 Install the vacuum accessory bracket and the mounting bolts ...

Page 1580: ... mounting nut 92 Position the vacuum harness and connect the vacuum hoses to the back of the supercharger 93 Connect the vacuum hose to the EGR valve 94 Connect the vacuum hoses to the fuel pulse damper and the EGR vacuum regulator solenoid ...

Page 1581: ...ator 96 Connect the vacuum hoses to the differential pressure feedback EGR system 97 Connect the electrical connectors to the fuel pulse damper EGR vacuum regulator solenoid supercharger bypass vacuum solenoid and the differential pressure feedback EGR system 98 Install the drain plug ...

Page 1582: ...d with metal surface cleaner Allow the surface to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure can result in future oil leakage Apply a 4 mm 0 16 in bead of silicone gasket and sealant around the rear oil seal retainer plate sealing surface Also apply a bead of silicone gasket and sealant at the junction where the cylinder block oil pan...

Page 1583: ... sequence shown Tighten bolts No 1 6 to 10 Nm 89 lb in Tighten bolts No 7 and 8 to 20 Nm 15 lb ft Tighten bolts No 7 and 8 an additional 60 degrees 103 Using the special tools install the crankshaft rear main seal 104 Using the special tool install the crankshaft oil slinger ...

Page 1584: ...105 Install the flywheel and the bolts Tighten the bolts in the sequence shown ...

Page 1585: ...2 Spreader Bar 303 D089 D93P 6001 A3 or equivalent Material Item Specification SAE 5W 20 Premium Synthetic Blend Engine Oil XO 5W20 QSP or equivalent WSS M2C153 H Motorcraft Premium Engine Coolant VC 4 A in Canada CXC 10 in Oregon VC 5 or equivalent ESE M97B44 A Motorcraft Premium Gold Engine Coolant VC 7 A in Oregon VC 7 B or equivalent WSS M97B51 A1 Threadlock and Sealer E0AZ 19554 AA WSK M2G351...

Page 1586: ...2 Remove the special tool 3 Remove the special tool 4 NOTE RH is shown LH is similar Install the RH and LH ignition coil covers 5 Install the clutch cable and retaining screws ...

Page 1587: ...e vehicle For additional information refer to Section 100 02 7 NOTE RH is shown LH is similar Install the two engine mount nuts 8 Install the degas bottle support bracket and the bolts 9 Install the ground strap and the bolt ...

Page 1588: ...ct the lower radiator hose 11 Connect the hose to the oil filter adapter 12 Attach the B terminal cable and install the nut 13 Connect the generator electrical connector 14 Install the ground cable and the nut ...

Page 1589: ...l the nut 16 NOTE RH is shown LH is similar Position the exhaust and install the manifold flange nuts 17 Connect the transmission wiring harness 1 Connect the RH oxygen sensor connector retainer 2 Connect the transmission harness electrical connector ...

Page 1590: ... crankshaft pulley For additional information refer to Crankshaft Pulley Auxiliary in this section 20 Install the battery tray and the mounting bolts 21 Position the power steering hose into the grommet 22 Install the bracket mounting bolt 23 Position the power steering hose and tighten the fitting ...

Page 1591: ...motor and shroud as an assembly and install the RH mounting bolt 25 Install the LH cooling fan mounting bolt 26 Connect the cooling fan electrical connector 27 Install the supercharger cooling hose assembly and tighten the clamps ...

Page 1592: ...the lower radiator hose to the coolant bypass tube 29 Install the supercharger degas bottle and the mounting bolts 30 Connect the supercharger degas hose 31 Install the power steering hose bracket and mounting nut ...

Page 1593: ...32 Install the power steering reservoir and the fasteners 33 Connect the power steering hoses 34 Install the engine coolant degas bottle and the fasteners 35 Install the degas bottle return hose ...

Page 1594: ...iator vent hose at the degas bottle 37 Install the radiator sight shield and the push pins 38 Install the hood prop 39 Install the A C muffler 1 Connect the A C tube and position the A C muffler 2 Install the bracket nut ...

Page 1595: ...ubricate the O rings with refrigerant oil Connect the A C tube peanut fittings at the condenser 41 NOTE Inspect the O rings and install new O rings if necessary NOTE Lubricate the O rings with refrigerant oil Connect the A C tube 42 Connect the A C tube at the accumulator ...

Page 1596: ...43 Connect the radiator upper hose the radiator lower hose and the supercharger degas hose 44 Connect the heater hoses 45 Install the wiring harness to the dash panel 46 Connect the vacuum hoses ...

Page 1597: ...pin electrical connectors 48 NOTE Install a new gasket if necessary Install the throttle body and spacer assembly and the mounting nuts 49 Position the accelerator and speed control cables 50 Install the accelerator cable bracket bolts ...

Page 1598: ...the accelerator cable If equipped connect the speed control cable 52 Connect the fuel tube spring lock coupling For additional information refer to Section 310 00 53 Connect the A C pressure switch electrical connector 54 Connect the vacuum hose ...

Page 1599: ...and the throttle position TP electrical connectors 56 Install the air cleaner outlet pipe and tighten the clamps 57 Connect the vacuum hose 58 Connect the breather hose 59 Connect the intake air temperature IAT sensor electrical connector ...

Page 1600: ... the crankcase with clean engine oil and check that all other fluids are at the correct levels 64 Fill and bleed the engine cooling system For additional information refer to Section 303 03A 65 Fill and purge the power steering system For additional information refer to Section 211 00 66 Start the engine and check for leaks Stop the engine and recheck the fluid levels 67 Charge the A C system For ...

Page 1601: ......

Page 1602: ...ications Description Specification GENERAL SPECIFICATIONS Displacement 4 6L 4V 281 CID Number of Cylinders 8 Bore and Stroke 90 2 x 90 0 mm 3 55 x 3 54 inch Firing Order 1 3 7 2 6 5 4 8 Oil Pressure HOT 1500 RPM 138 310 kPa Drive Belt Tension a Combustion Chamber Volume cc 52 6 0 5 cm c Valve Seats Width Intake 1 8 2 2 mm 0 071 0 086 inch Width Exhaust 1 8 2 2 mm 0 071 0 086 inch Angle 45 degrees ...

Page 1603: ... 1 4228 inch Exhaust 289 1 N 36 14 mm 64 99 Lb Ft 1 4228 inch Service Limit 10 Pressure Loss 28 02 mm 1 103 inch Roller Follower Ratio 1 8 1 Hydraulic Lash Adjuster Diameter Std 16 000 15 988 mm 0 6299 0 6294 inch Clearance to Bore 0 018 0 069 mm 0 000709 0 002717 inch Service Limit 0 016 mm 1 0006299 inch Hydraulic Leakdown Rate d 5 25 seconds Collapsed Lash Adjuster Gap Desired 0 80 1 20 mm 0 03...

Page 1604: ...earing Wall Thickness Std f 1 920 1 928 mm 0 075591 0 075905 inch Main Bearings Clearance to Crankshaft Desired 0 025 0 045 mm 0 00098 0 00177 inch Allowable 0 025 0 050 mm 0 00098 0 00197 inch Bearing Wall Thickness Std f 2 451 mm 0 0965 inch Connecting Rod Pin Bore Diameter 22 012 22 024 mm 0 86661 0 86708 inch Crankshaft Bearing Bore Diameter 56 866 56 886 mm 2 23881 2 23960 inch Length Center ...

Page 1605: ...ore Clearance 0 010 0 026 mm 0 0003937 0 0010236 inch Pin Bore Diameter 21 9985 22 0025 mm 0 866081 0 866238 inch Ring Groove Width Compression Top 1 230 1 250 mm 0 484 0 0492 inch Compression Bottom 1 520 1 540 mm 0 05984 0 06062 inch Oil Ring 3 030 3 055mm Piston Pin Length 61 601 62 030 mm 2 42523 2 44212 inch Diameter 22 0005 22 0030 mm 0 8661596 0 8662581 inch Pin to Piston Fit j 0 0045 0 002...

Page 1606: ... a a a Exhaust manifold studs 25 18 Lower intake manifold to cylinder head bolt a a a Main bearing cap bolt a a a Oil filter adapter bolt 25 18 Oil bypass filter to adapter 50 37 Oil pump screen cover and tube to oil pump bolt 10 89 Oil pan to cylinder block bolt a a a Oil pan to engine front cover bolts a a a Oil pump to cylinder block bolt 10 89 Oil pump screen and pickup tube to main bearing ca...

Page 1607: ...s 10 89 Oil pump screen and pickup tube spacer to main bearing stud 25 18 Accelerator cable bracket 10 89 Belt idler pulley bolt 25 18 Sub frame brace nuts 41 30 Air intake scoop bolts 25 18 Air intake scoop bracket bolt 25 18 Air intake scoop bracket nuts 25 18 Air intake scoop bracket throttle body nut 9 80 Exhaust gas recirculation EGR vacuum regulator solenoid bolts 10 89 ...

Page 1608: ...se codes contain all the pertinent information relating to the dates optional equipment and revisions The Ford Master Parts Catalog contains a complete listing of the codes and their application Code Information The engine code information label located on the side of the valve cover and the front side of the valve cover contains the following engine build date engine plant code engine code Exhaus...

Page 1609: ... crankshaft to lubricate the connecting rod bearings Controlled leakage through the crankshaft main bearings and connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls as well as the entire connecting rod piston and piston rings assembly The left cylinder head is fed from a drilling into the supply passage feeding the main gallery at the front of the cylinder bl...

Page 1610: ...ng system includes the following radiator coolant pump the electric cooling fan motor and fan blade activated by the variable control module the degas bottle which aids in maintaining the correct volume of engine coolant thermostat upper radiator hose lower radiator hose heater coolant hoses Drive Belt System The 4 6L 4V DOHC engine is equipped with a serpentine drive belt To ensure maximum life a...

Page 1611: ...Item Part Number Description 1 9D476 EGR valve gasket 2 9D460 EGR valve 3 9D477 EGR valve to exhaust manifold tube 4 W701625 Bolt 2 req d ...

Page 1612: ...ption 1 N806154 Bolt 4 req d 2 N705654 Bolt 3 9F670 Idle air control valve gasket 4 9F715 Idle air control valve 5 N806154 Bolt 2 req d 6 N806154 Bolt 5 req d 7 9J433 Differential pressure feedback EGR 8 W701557 Screw 2 req d ...

Page 1613: ...ection supply manifold 13 N811449 Stud 4 req d 14 9E498 Vacuum harness 15 W704682 Bolt 10 req d 16 9J447 Intake manifold lower 17 8548 Coolant crossover 18 9F593 Fuel Injector 8 req d 19 N605892 Bolt 2 req d 20 9728 Bracket 21 9424 Intake manifold upper 22 9E936 Throttle body gasket 23 9E926 Throttle body ...

Page 1614: ...Number Description 1 6083 Cylinder head gasket 2 Bolt 2 req d 3 Washer 2 req d 4 6255 Spacer 5 Secondary timing chain 2 req d 6 Screw and washer 7 6C271 Timing chain vibration damper 8 6B277 Camshaft bearing cap ...

Page 1615: ...earing cap 2 req d 16 9448 Exhaust manifold gasket 17 9F485 EGR valve tube to manifold connector 18 W701706 Nut 8 req d 19 9431 Exhaust manifold 20 6C324 PCV tube 21 6A505 Valve cover 22 W708442 Stud bolt 4 req d 23 N808199 Bolt 16 req d 24 6766 Oil filler cap 25 12A366 Ignition coils 26 6P068 Ignition coil cover 27 N807309 Bolt 4 req d 28 6050 Cylinder head ...

Page 1616: ...Item Part Number Description 1 N808102 Bolt 2 N808102 Bolt 3 19A216 Belt idler pulley 4 N806155 Bolt 5 6B288 Camshaft position sensor 6 N606543 Bolt 4 req d 7 6L266 Timing chain tensioner 8 W705803 Stud ...

Page 1617: ... arm 18 6306 Crankshaft sprocket 19 12A227 Ignition pulse ring 20 3A696 Power steering pump 21 N806176 Bolt 4 req d 22 3R801 Gasket 23 3A696 Power steering pump pulley 24 W706508 Stud 25 N806177 Bolt 8 req d 26 N808586 Stud 27 N806300 Stud 4 req d 28 6700 Crankshaft front seal 29 N806155 Bolt 30 6C315 Crankshaft position sensor 31 W706560 Stud 32 6C086 Engine front cover 33 N806165 Washer 34 N8061...

Page 1618: ...lt 2 req d 2 6211 Connecting rod bearing 16 req d 3 6140 Piston pin retainer 16 req d 4 6135 Piston pin 8 req d 5 6110 Piston 8 req d 6 6159 Piston ring 8 req d 7 6159 Piston ring 8 req d part of 6100 8 6150 Piston ring 8 req d part of 6100 ...

Page 1619: ...49 Cylinder head 18 6C527 Spark plug gasket 8 req d 19 6200 Connecting rod 8 req d 20 6200 Connecting rod 8 req d 21 6161 Piston ring 8 req d Item Part Number Description 1 8555 Coolant bypass tube 2 6750 Oil level indicator 3 6754 Oil level indicator tube 4 N806155 Bolt 5 6C358 Bolt 10 req d 6 6714 Oil bypass filter 7 N806156 Bolt 4 req d 8 9278 Oil pressure sender 9 6881 Oil filter adapter 10 6A...

Page 1620: ...nsor 2 req d 7 N807309 Bolt 2 req d 8 18696 Heater water hose 9 7120 Pilot bearing 10 6K318 Crankshaft rear retainer 11 N806155 Bolt 6 req d 12 6310 Crankshaft oil slinger 13 6375 Flexplate 14 N806168 Bolt 6 req d 15 Flywheel 16 N808139 Bolt 8 req d 17 7550 Clutch disc 18 7563 Clutch pressure plate 19 N808969 Bolt 6 req d 20 6701 Crankshaft rear oil seal 21 N806007 Dowel pin 2 req d ...

Page 1621: ...Part Number Description 1 N806177 Bolt 4 req d 2 N806459 Dowel 4 req d 3 6A341 Thrust washer 4 6303 Crankshaft 5 6A339 Thrust bearing 6 6325 Main bearing cap 5 req d 7 6345 Bolt 10 req d 8 6K258 Stud 4 req d ...

Page 1622: ...d 15 6622 Oil pump screen pickup and tube 16 N806155 Bolt 2 req d 17 N806180 Nut 2 req d 18 6345 Bolt 6 req d 19 6C360 Main bearing cap adjusting screw 10 req d 20 6A338 Crankshaft main bearing 4 req d 21 N806201 Woodruff key 22 6621 Oil pump 23 N806183 Bolt 4 req d 24 6333 Crankshaft main bearing 25 8501 Coolant pump ...

Page 1623: ... Engine Refer to Section 303 00 for basic mechanical concerns or refer to the Powertrain Control Emissions Diagnosis PC ED manual for driveability concerns SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1624: ...ditional information refer to Section 303 12 3 Disconnect the accelerator cable the speed control actuator cable and the return spring 4 Remove the bolts disconnect the clip and position the cables out of the way 5 Disconnect the throttle position TP sensor 6 Disconnect the evaporative emissions EVAP return hose SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1625: ...he differential pressure feedback EGR 8 Disconnect the main chassis vacuum supply line and the EGR valve vacuum line 9 Disconnect the differential pressure feedback EGR hoses 10 Disconnect the EGR valve to exhaust manifold tube from the EGR valve ...

Page 1626: ...e vacuum lines from the EGR vacuum regulator solenoid 12 Remove the PCV valve to intake manifold tube 13 Remove the upper intake manifold bolts in the sequence shown and remove the intake manifold assembly 14 Inspect and clean the sealing surfaces ...

Page 1627: ...pper intake manifold gasket 2 Install the intake manifold and bolts in the sequence shown 3 Install the PCV valve to intake manifold tube 4 Connect the vacuum hoses and the electrical connector to the EGR vacuum regulator solenoid ...

Page 1628: ...R valve 6 Connect the hoses to the differential pressure feedback EGR 7 Connect the main chassis vacuum supply line and the EGR valve vacuum line 8 Connect the IAC valve and the differential pressure feedback EGR electrical connectors ...

Page 1629: ...ct the EVAP return hose 10 Connect the TP sensor 11 Position the cables and bracket Install the bolts connect the clip 12 Connect the throttle cable the speed control actuator cable and throttle return spring ...

Page 1630: ...13 Install the air cleaner outlet tube For additional information refer to Section 303 12 14 Install the air intake scoop bracket For additional information refer to Section 303 12 ...

Page 1631: ...to Section 303 03A 4 Remove the generator For additional information refer to Section 414 02 5 Disconnect the electrical connector and the vacuum line from the fuel pressure sensor 6 Disconnect the eight fuel injector electrical connectors 7 Separate the fuel charging wiring harness from the fuel injection supply manifold studs in three places SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Wor...

Page 1632: ...take manifold slightly 9 Disconnect the fuel charging wiring harness from the rear of the lower intake manifold and remove the manifold 10 Remove the intake manifold gaskets Clean and inspect the sealing surfaces Installation 1 Install the lower intake manifold gaskets ...

Page 1633: ...manifold and install the manifold 3 Install the intake manifold fasteners and tighten in the sequence shown 4 Position the fuel charging wiring harness and connect it to the fuel injection supply manifold in three places 5 Connect the eight fuel injector electrical connectors ...

Page 1634: ...itional information refer to Section 414 02 8 Install the coolant bypass tube For additional information refer to Section 303 03A 9 Connect the fuel line For additional information refer to Section 310 00 10 Install the upper intake manifold For additional information refer to Intake Manifold Upper in this section ...

Page 1635: ...ir cleaner outlet tube For additional information refer to Section 303 12 5 Remove the RH ignition coil cover bolts and the cover 6 Disconnect the ignition coil electrical connectors SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual Material Item Specification Metal Surface Cleaner F4AZ 19A536 RA or equivalent WSE M5B392 A Silicone Gasket and Sealant F7AZ 19554 EA or equivalent WS...

Page 1636: ...al information refer to Section 303 04D 9 Disconnect the fuel tube spring lock coupling For additional information refer to Section 310 00 10 Disconnect the heater hose 11 Disconnect the A C suction tube at the accumulator 12 Disconnect and remove the A C suction tube ...

Page 1637: ... separate the A C tube from the condenser 14 Disconnect the A C tube at the evaporator 15 Remove the A C tube 1 Disconnect the pin type retainer 2 Remove the A C tube 16 Disconnect the evaporative emissions EVAP return tube ...

Page 1638: ... abrasive discs or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges which make leak paths Use a plastic scraping tool to remove all traces of old sealant Clean and inspect the sealing surfaces and inspect the valve cover gaskets If necessary install new gaskets Make sure the gaskets are correctly seated on the valve cover ...

Page 1639: ... to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure can cause future oil leakage Apply a bead of silicone gasket and sealant in two places where the engine front cover meets the cylinder head 2 Install the RH valve cover and finger tighten the bolts 3 Tighten the RH valve cover bolts in the sequence shown ...

Page 1640: ...harness to the valve cover stud bolt 5 Connect the evaporative emissions EVAP return tube 6 NOTE Lubricate O ring with clean PAG oil or equivalent Install the A C tube 1 Install the A C tube 2 Connect the pin type retainer ...

Page 1641: ...icate O ring with clean PAG oil or equivalent Connect the A C tube to the evaporator 8 Connect the A C tube and install the nut 9 NOTE Lubricate O ring with clean PAG oil or equivalent Install the A C suction tube ...

Page 1642: ...mulator 11 Connect the heater hose 12 Install the throttle body For additional information refer to Section 303 04D 13 Connect the fuel tube spring lock coupling For additional information refer to Section 310 00 14 Install the RH ignition coils 15 Connect the RH ignition coil electrical connectors ...

Page 1643: ... For additional information refer to Section 303 12 18 Connect the battery ground cable For additional information refer to Section 414 01 19 Fill the cooling system For additional information refer to Section 303 03A 20 Recharge the A C system For additional information refer to Section 412 00 ...

Page 1644: ...nd support the vehicle For additional information refer to Section 100 02 Manual transmission vehicles 4 Remove the screw and the dust shield 5 Disengage the clutch release cable from the clutch release fork SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual Material Item Specification Metal Surface Cleaner F4AZ 19A536 RA or equivalent WSE M5B392 A Silicone Gasket and Sealant F7AZ ...

Page 1645: ...e 7 Remove the two screws and position the clutch release cable aside All vehicles 8 Remove the LH ignition coil cover bolts and the cover 9 Disconnect the ignition coil electrical connectors 10 Remove the ignition coils ...

Page 1646: ...osition the oil level indicator tube aside 12 Disconnect the positive crankcase ventilation PCV valve hose and the electrical connector 13 Disconnect the wiring harness anchor from the valve cover 14 Remove the LH valve cover ...

Page 1647: ... necessary install new gaskets Make sure the gaskets are correctly seated on the valve cover Installation All vehicles 1 NOTE If the valve cover is not secured within four minutes the sealant must be removed and the sealing area cleaned with metal surface cleaner Allow to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure can result in future...

Page 1648: ...Tighten the LH valve cover bolts in the sequence shown 4 Connect the wiring harness anchor to the valve cover stud bolt 5 Connect the positive crankcase ventilation PCV valve hose and electrical connector ...

Page 1649: ...6 Position the oil level indicator tube and install the bolt 7 Install the LH ignition coils 8 Connect the ignition coil electrical connectors 9 Install the LH ignition coil cover and the bolts ...

Page 1650: ... the clutch release cable and install the two screws 11 Raise and support the vehicle For additional information refer to Section 100 02 12 Connect the clutch release cable to the clutch release fork 13 Install the dust shield and the screw ...

Page 1651: ...Lower the vehicle All vehicles 15 Install the Hydro Boost brake booster For additional information refer to Section 206 07 16 Install the air intake scoop For additional information refer to Section 303 12 ...

Page 1652: ...d support the vehicle For additional information refer to Section 100 02 3 Remove the bolt 4 Using the special tool remove the crankshaft pulley SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Remover Crankshaft Vibration Damper 303 009 T58P 6316 D Installer Crankshaft Vibration Damper 303 102 T74P 6316 B ...

Page 1653: ...eeting Ford specification WSE M4G323 A4 2 Using the special tool install the crankshaft pulley 3 Install the bolt and washer Tighten the bolt in four stages Stage 1 Tighten the bolt to 90 Nm 66 lb ft Stage 2 Loosen the bolt one full turn Stage 3 Tighten the bolt to 50 Nm 37 lb ft Stage 4 Tighten the bolt an additional 90 degrees 4 Lower the vehicle 5 Install the accessory drive belt For additional...

Page 1654: ......

Page 1655: ... crankshaft front oil seal SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Crankshaft Seal Installer Aligner 303 335 T88T 6701 A Front Cover Seal Remover 303 107 T74P 6700 A Crankshaft Seal Installer 303 635 Crankshaft Damper Replacer 303 102 T74P 6316 B Material Item Specification Super Premium SAE 5W 20 Engine Oil XO 5W20 QSP or equivalent WSS M2C153 H ...

Page 1656: ...er and the crankshaft front oil seal inner lip with clean engine oil 2 Using the special tools install the crankshaft front oil seal into the engine front cover 3 Install the crankshaft pulley For additional information refer to Crankshaft Pulley ...

Page 1657: ......

Page 1658: ...nformation refer to Section 206 07 Manual transmission vehicles 4 Remove the two clutch release cable retaining screws All vehicles 5 Remove the LH ignition coil cover bolts and the cover SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual Material Item Specification Metal Surface Cleaner F4AZ 19A536 RA or equivalent WSE M5B392 A Silicone Gasket and Sealant F7AZ 19554 EA or equivale...

Page 1659: ...ion coil electrical connectors 7 Remove the ignition coils 8 Remove the bolt and position the oil level indicator tube aside 9 Remove the positive crankcase ventilation PCV valve hose and disconnect the electrical connector ...

Page 1660: ...10 Disconnect the wiring harness anchor from the valve cover 11 Remove the degas bottle vent hose 12 Remove the degas bottle return hose 13 Remove the nuts and the degas bottle ...

Page 1661: ...he upper radiator hose from the bypass tube 15 Disconnect the lower radiator hose from the bypass tube 16 Disconnect the cooling fan electrical connector 17 Separate the cooling fan wiring harness from the fan shroud ...

Page 1662: ...g fan shroud bolt 20 Remove the cooling fan and shroud as an assembly 21 Remove the crankshaft front oil seal For additional information refer to Crankshaft Front Oil Seal 22 Remove the three bolts shown Loosen the fourth bolt hidden behind the p s tube Position the ...

Page 1663: ...move the A C muffler bracket nut 24 Remove the bolts and position the A C compressor aside 25 Disconnect the crankshaft position CKP sensor electrical connector 26 Remove the wiring harness nuts and position the wiring harness aside ...

Page 1664: ... the oil Install the drain plug when finished 28 Remove the front four oil pan bolts Manual transmission vehicles 29 Remove the bolt and the clutch release cable shield 30 Disengage the clutch release cable from the clutch release fork ...

Page 1665: ...o clean the sealing surfaces These tools cause scratches and gouges which make leak paths Use a plastic scraping tool to remove all traces of old sealant Clean and inspect sealing surfaces and valve cover gaskets If necessary install new gaskets Make sure the gaskets are correctly seated on the valve cover 34 Remove the four bolts and the coolant pump pulley ...

Page 1666: ...d position the power steering reservoir and bracket assembly aside 36 Disconnect the camshaft position CMP sensor electrical connector 37 Remove the idler pulleys 38 Remove the bolts and the studs and remove the engine front cover ...

Page 1667: ... Installation All vehicles 1 Position the engine front cover gasket on the engine front cover 2 NOTE If the engine front cover is not secured within four minutes the sealant must be removed and the sealing area cleaned with metal surface cleaner Allow to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure can cause future oil leakage Apply the...

Page 1668: ...Hex Flange Head Pilot M8 x 1 25 x 53 5 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 6 W706508 Stud Hex Shldr Pilot M8 x 1 25 x 50 M6 x 1 x 10 7 N808586 Stud and Washer Hex Head Pilot M8 x 1 25 x 60 M6 x 1 x 26 8 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 9 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 10 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 11 N806300 Stud Hex Shldr Pi...

Page 1669: ...ower steering reservoir and bracket assembly and install the bolts 7 Install the coolant pump pulley and the bolts 1 25 x 16 13 N806300 Stud Hex Shldr Pilot M8 x 1 25 x 65 M8 x 1 25 x 26 14 N806300 Stud Hex Shldr Pilot M8 x 1 25 x 65 M8 x 1 25 x 26 15 N806300 Stud Hex Shldr Pilot M8 x 1 25 x 65 M8 x 1 25 x 26 ...

Page 1670: ...all the bolts 9 Tighten the LH valve cover bolts in the sequence shown 10 Raise and support the vehicle For additional information refer to Section 100 02 Manual transmission vehicles 11 Connect the clutch release cable to the clutch release fork ...

Page 1671: ... the four oil pan bolts Tighten the bolts in three stages and in the sequence shown 1 Stage 1 Tighten the bolts to 2 Nm 18 lb in 2 Stage 2 Tighten the bolts to 20 Nm 15 lb ft 3 Stage 3 Tighten the bolts an additional 90 degrees 1 4 turn 14 Position the wiring harness and install the nuts ...

Page 1672: ...nkshaft position CKP sensor electrical connector 16 Position the A C compressor A C muffler and the hose Install the bolts 17 Install the A C muffler bracket nut 18 Position the power steering pump and install the bolts ...

Page 1673: ... information refer to Crankshaft Front Oil Seal in this section 20 Position the cooling fan and shroud in the installed position 21 Install the RH cooling fan bolt 22 Install the LH cooling fan bolt 23 Attach the cooling fan wiring harness to the fan shroud ...

Page 1674: ...24 Connect the cooling fan electrical connector 25 Connect the lower radiator hose to the bypass tube 26 Connect the upper radiator hose to the bypass tube 27 Install the degas bottle and the nuts ...

Page 1675: ...degas bottle return hose 29 Connect the degas bottle vent hose 30 Connect the wiring harness anchor to the valve cover 31 Install the positive crankcase ventilation PCV valve hose and connect the electrical connector ...

Page 1676: ...32 Position the oil level indicator tube and install the bolt 33 Install the LH ignition coils 34 Connect the LH ignition coil electrical connectors 35 Install the LH coil cover and install the bolts ...

Page 1677: ...valve cover For additional information refer to Valve Cover RH in this section 38 Install the Hydro Boost brake booster For additional information refer to Section 206 07 39 Install the air intake scoop bracket For additional information refer to Section 303 12 40 Fill the crankcase with clean engine oil ...

Page 1678: ......

Page 1679: ...ation refer to Engine Front Cover in this section 2 Remove the crankshaft sensor ring from the crankshaft 3 CAUTION Unless otherwise instructed at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the camshaft to be rotated Severe piston and valve damage will occur Using the special tool position the crankshaft as shown SECTION 303 01D Engine Mach...

Page 1680: ...lar Remove the two bolts the timing chain tensioner and tensioner arm 6 CAUTION Unless otherwise instructed at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the camshaft to be rotated Severe piston and valve damage will occur Remove the LH and RH timing chains and the crankshaft sprocket Remove the special tool from the crankshaft Remove the R...

Page 1681: ...olts and the timing chain guides Installation 1 CAUTION Timing chain procedures must be followed exactly or damage to the pistons or valves will result Compress the tensioner plunger using a soft jawed vise 2 Install a retaining clip on the tensioner to hold the plunger in during installation Remove the tensioner from the vise ...

Page 1682: ...s 4 Install the timing chain guides 5 Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o clock position Rotate the RH camshaft timing sprocket until the timing mark is approximately in the 11 o clock position 6 CAUTION Unless otherwise instructed at no time when the timing chains are ...

Page 1683: ...r severe piston or valve damage will occur Using the special tool position the crankshaft 7 Remove the special tool 8 Install the crankshaft sprocket with the flange facing forward 9 NOTE LH timing chain shown RH similar Install the LH timing chain onto the crankshaft sprocket aligning the one copper link on the timing chain with the slot on the crankshaft sprocket 10 Verify the camshaft sprocket ...

Page 1684: ...d tensioners and install the bolts 12 Remove the retaining clips from the timing chain tensioners 13 Position the crankshaft sensor ring on the crankshaft 14 Install the engine front cover For additional information refer to Engine Front Cover in this section ...

Page 1685: ......

Page 1686: ...r pressure has forced the piston to the bottom of the cylinder any loss of air pressure will allow the valve to fall into the cylinder If air pressure must be removed support the valve prior to removal Use compressed air in the cylinder to hold both valves in position SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Compressor Valve Spring 303 452 T93P 6565 AR Inst...

Page 1687: ...sually inspected if new seals are not installed Remove the valve spring retainer keys the valve spring retainer the valve spring and the valve stem seal 7 Using the special tool compress the exhaust valve spring 8 NOTE Valve stem seals should be visually inspected if new seals are not installed ...

Page 1688: ...e valve stem seal Installation 1 Using the special tools install the new intake valve stem seals 2 Using the special tools install the new exhaust valve stem seals 3 Install the Valve Spring Compressor Spacer between the valve spring coils to protect the intake valve stem seal from damage ...

Page 1689: ...o protect the intake valve stem seal from damage 6 Using the special tool install the exhaust valve spring the spring retainer and the valve spring retainer keys 7 Remove the compressed air hose from the cylinder 8 Install the spark plugs For additional information refer to Section 303 07C 9 Install the roller followers For additional information refer to Roller Followers in this section ...

Page 1690: ......

Page 1691: ...nformation refer to Roller Followers in this section 2 Remove the 16 hydraulic lash adjusters 3 Inspect the roller followers For additional information refer to Section 303 00 Installation 1 To install reverse the removal procedure SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1692: ...he special tool compress the intake valve spring and remove the roller follower 4 Using the special tool compress the exhaust valve spring and remove the roller follower 5 Repeat Steps 2 3 and 4 to remove all the necessary roller followers Inspect roller finger followers and camshafts For additional information refer to Section 303 00 6 To install reverse the removal procedure SECTION 303 01D Engi...

Page 1693: ......

Page 1694: ...e For additional information refer to Timing Drive Components in this section 3 Install the special tool 4 Remove the exhaust camshaft sprocket and the intake camshaft bolt washer and spacer SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Holding Tool Camshaft 303 446 T93P 6256 AHR Material Item Specification Super Premium SAE 5W 20 Engine Oil XO 5W20 QSP or equiv...

Page 1695: ...5 Remove the special tool 6 Compress the tensioner and install a lock pin 7 Remove the timing chain the sprocket and intake camshaft sprocket spacer 8 NOTE LH shown RH similar Remove the bolts ...

Page 1696: ...ap exhaust are longer and must be returned to the same location or engine damage may occur NOTE Identify the camshaft to cylinder head location Caps are not interchangeable Remove the bolts and the camshaft bearing cap assemblies 10 Remove the camshafts ...

Page 1697: ...Installation 1 NOTE LH shown RH similar Install the camshafts Lubricate the camshafts with clean engine oil 2 Install the camshaft bearing cap assemblies and tighten the bolts in the sequence shown ...

Page 1698: ...3 Install the bolts 4 CAUTION Timing marks must be at 12 o clock and indexed at 6 o clock Install the camshaft sprockets and the chain as an assembly 5 Remove the lockpin from the chain tensioner ...

Page 1699: ... the camshaft spacer washer and bolt and hand tighten the bolt 8 Install the camshaft sprocket washer and bolt and hand tighten the bolt 9 Tighten the bolts in two stages Stage 1 Tighten to 40 Nm 30 lb ft Tighten an additional 90 degrees ...

Page 1700: ...timing chain for the left side or both timing chains for the right side For additional information refer to Timing Drive Components in this section 12 Install the roller followers For additional information refer to Roller Followers in this section ...

Page 1701: ...verter Y pipe For additional information refer to Section 309 00 4 Remove the starter For additional information refer to Section 303 06 5 Remove the exhaust manifold 1 Remove the nuts 2 Remove the exhaust manifold 3 Remove and discard the gasket 6 To install reverse the removal procedure Use a new exhaust manifold gasket Tighten the exhaust manifold nuts in the sequence shown SECTION 303 01D Engi...

Page 1702: ......

Page 1703: ...n refer to Section 414 01 3 Raise the vehicle For additional information refer to Section 100 02 4 Remove the dual converter Y pipe For additional information refer to Section 309 00 5 Remove and discard the pinch bolt 6 Separate the steering coupler 7 Disconnect the exhaust gas recirculation EGR tube at the exhaust manifold SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1704: ...e the nuts 2 Remove the exhaust manifold 3 Remove and discard the gasket 9 Remove the oil level indicator tube 10 Remove and discard the exhaust manifold gasket 11 To install reverse the removal procedure Use a new exhaust manifold gasket ...

Page 1705: ......

Page 1706: ... 2 Disconnect the lower radiator hose 3 Raise the vehicle For additional information refer to Section 100 02 4 Drain the engine oil 5 Remove the oil filter adapter 1 Remove the oil filter 2 Remove the bolts 3 Remove the oil filter adapter 4 Remove the gasket SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1707: ...n and inspect the oil filter adapter Flush the oil filter adapter with parts cleaner If metal particles are present in the adapter install a new adapter Installation 1 To install reverse the removal procedure ...

Page 1708: ...or 2 Remove the LH exhaust manifold For additional information refer to Exhaust Manifold LH in this section 3 Remove the bolt 4 Remove the oil level indicator tube Installation 1 To install reverse the removal procedure SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1709: ......

Page 1710: ...move the radiator sight shield 6 Remove the manifold and tube assembly accumulator to compressor 4 6L For additional information refer to Section 412 03 SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Compressor Coil Spring 204 D001 D78P 5310 A Lifting Bracket Engine 303 D088 D93P 6001 A2 3 Bar Engine Support Kit 303 F072 Material Item Specification Metal Surface ...

Page 1711: ... to Section 412 03 8 Install the special tools 9 Install the special tool 10 Raise the vehicle on a hoist For additional information refer to Section 100 02 11 Remove the two engine mount nuts 12 Lower the vehicle 13 Using the special tool raise the engine ...

Page 1712: ...14 Raise the vehicle on a hoist 15 Remove the oil pan drain plug and drain the engine oil 16 Using the special tool compress the front coil springs 17 Position a safety stand 18 Remove the four bolts ...

Page 1713: ...NOTE Do not completely remove the bolts Loosen the bolts 20 Lower the front sub frame 21 Remove the sub frame brace 22 Remove the starter wiring harness nuts and position the wiring harness out of the way ...

Page 1714: ...n and inspect the mating surfaces 2 NOTE If the oil pan is not secured within four minutes the sealant must be removed and the sealing area cleaned with metal surface cleaner Allow to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure may result in future oil leakage Apply silicone gasket and sealant at the engine front cover to cylinder bloc...

Page 1715: ...ilicone gasket and sealant at the rear oil seal retainer to cylinder block sealing surface 4 Install the oil pan and gasket and loosely install the bolts 5 Tighten the bolts in the sequence shown in three stages Stage 1 Tighten to 2 Nm 18 lb in Stage 2 Tighten to 20 Nm 15 lb ft Stage 3 Tighten an additional 60 degrees ...

Page 1716: ...6 Install the oil pan drain plug 7 Position the starter wiring harness and install the wiring harness nuts 8 Install the sub frame brace ...

Page 1717: ...9 Raise the front sub frame into position 10 Install the two bolts 11 Install the two bolts 12 Install the four bolts ...

Page 1718: ...safety stand aside 14 Release the tension from the front coil springs and remove the special tool 15 Raise the vehicle 16 Using the special tool lower the engine and remove the special tool 17 Remove the special tools ...

Page 1719: ...tion 412 03 23 Install the manifold and tube assembly accumulator to compressor 4 6L For additional information refer to Section 412 03 24 Install the radiator sight shield 25 Install the air cleaner outlet tube For additional information refer to Section 303 12 26 Install the air intake scoop For additional information refer to Section 303 12 27 Install the battery ground cable For additional inf...

Page 1720: ......

Page 1721: ...e transmission For additional information refer to Section 307 01 2 Remove the bolts in the sequence shown and remove the flexplate 3 To install reverse the removal procedure SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1722: ......

Page 1723: ...Remove the clutch components For additional information refer to Section 308 01 2 Remove the bolts and the flywheel Installation 1 To install reverse the removal procedure SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1724: ...95P 6701 DH Remover Crankshaft Rear Oil Seal 303 519 T95P 6701 EH Installer Crankshaft Rear Oil Seal 303 516 T95P 6701 BH Remover Crankshaft Rear Oil Slinger 303 514 T95P 6701 AH Installer Crankshaft Rear Oil Slinger 303 517 T95P 6701 CH Impact Slide Hammer 100 001 T50T 100 A Material Item Specification Super Premium SAE 5W 20 Engine Oil XO 5W20 QSP or equivalent WSS M2C153 H ...

Page 1725: ...Remove the flywheel For additional information refer to Flywheel in this section All vehicles 3 Using the special tools remove the crankshaft oil slinger 4 Using the special tools remove the crankshaft rear oil seal Installation All vehicles 1 Using the special tools install the crankshaft rear oil seal Lubricate the oil seal using clean engine oil ...

Page 1726: ...aft oil slinger Manual transmission vehicles 3 Install the flywheel For additional information refer to Flywheel in this section Automatic transmission vehicles 4 Install the flexplate For additional information refer to Flexplate in this section ...

Page 1727: ...or additional information refer to Section 303 03A 3 Rotate the drive belt tensioner clockwise and detach the drive belt from the generator pulley 4 Disconnect the generator electrical connections SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Support Bracket Engine 303 639 3 Bar Engine Support Kit 303 F072 Alignment Tool Subframe 502 004 ...

Page 1728: ...ove the bolts and the generator 6 Install the special tool 7 Using the special tool support the engine 8 Remove the front springs For additional information refer to Section 204 01 9 NOTE RH shown LH similar ...

Page 1729: ...Remove the six splash shield pushpins 10 Remove the 13 bolts and the cross brace support 11 NOTE RH shown LH similar Remove the two engine mount nuts 12 Using two jackstands support the subframe ...

Page 1730: ...reference NOTE RH shown LH similar Remove the four bolts 14 NOTE RH shown LH similar Remove the four bolts 15 Using the jackstands lower the front subframe RH mount 16 Remove the nut and detach the wiring harness 17 Remove the bolts the studbolt and the engine mount ...

Page 1731: ...LH mount 18 Remove the nuts and detach the ground cables 19 Remove the bolt the studbolts and the engine mount Installation LH mount 1 Position the engine mount and install the bolt and studbolts ...

Page 1732: ...2 Attach the ground cables and install the nuts RH mount 3 Position the engine mount and install the bolts and studbolt 4 Attach the wiring harness and install the nut Both mounts ...

Page 1733: ...raise the subframe into position 6 NOTE RH shown LH similar Using the special tool align the subframe 7 NOTE RH shown LH similar Install the four bolts 8 NOTE RH shown LH similar Install the four bolts 9 Remove the jackstands ...

Page 1734: ...10 NOTE RH shown LH similar Install the two engine mount nuts 11 Position the cross brace support and install the 13 bolts 12 NOTE RH shown LH similar Install the six splash shield pushpins ...

Page 1735: ... front springs For additional information refer to Section 204 01 14 Remove the special tool 15 Remove the special tool 16 Position the generator and install the bolts 17 Connect the generator electrical connections ...

Page 1736: ...erator pulley Make sure the drive belt is routed correctly and is aligned correctly installed on each pulley 19 Connect the battery ground cable For additional information refer to Section 414 01 20 Install the coolant bypass tube For additional information refer to Section 303 03A ...

Page 1737: ...the hood to body ground strap 3 NOTE Mark the hood hinge locations to aid in hood installation Remove the four nuts and the hood SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Lifting Bracket Engine 303 D087 D93P 6001 A1 Lifting Bracket Engine 303 D088 D93P 6001 A2 Spreader Bar 303 D089 D93P 6001 A3 ...

Page 1738: ... Section 303 12 6 Disconnect the air cleaner outlet pipe at the throttle body 1 Disconnect the positive crankcase ventilation PCV inlet tube 2 Loosen the clamp and disconnect the outlet pipe 7 Disconnect the mass airflow sensor electrical connector 8 Remove the air cleaner 1 Remove the bolt 2 Remove the air cleaner and the outlet pipe as an assembly ...

Page 1739: ...itional information refer to Section 303 03A 11 Disconnect the fuel tube spring lock coupling For additional information refer to Section 310 00 12 Remove the upper radiator hose 8260 13 Disconnect the throttle cable and the speed control cable and remove the throttle return spring ...

Page 1740: ...e cables and the bracket aside 15 Disconnect the evaporative emissions return line 16 Disconnect the 16 pin and the 42 pin connectors 17 Separate the engine control sensor wiring in three locations and position onto the engine 18 Disconnect the vacuum hoses ...

Page 1741: ...19 Disconnect the heater hoses 20 Remove the wiring support bracket 21 Disconnect the connectors 22 Raise the cover and remove the nut and cables ...

Page 1742: ...3 Disconnect the hose from the coolant bypass tube 24 Disconnect the A C suction tube from the accumulator 25 Disconnect and remove the A C suction tube 26 Disconnect the A C tube Position A C tube aside ...

Page 1743: ...bracket bolts will be installed when the vehicle is raised Position the RH lifting bracket 28 Install the LH lifting bracket 29 Disconnect the radiator vent hose from the degas bottle 30 Remove the degas bottle return hose ...

Page 1744: ...tion 307 01 or Section 308 03B 33 Remove the dual converter H pipe For additional information refer to Section 309 00 34 Drain the engine oil Install the drain plug when finished 35 Position the A C muffler aside 1 Remove the bracket retainer 2 Disconnect the A C tube and position the A C muffler aside ...

Page 1745: ...he six o clock position 39 CAUTION the driveshaft flange fits tightly on the rear axle pinion flange pilot Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange Pry only in the area shown with a suitable tool to disconnect the driveshaft flange from the pinion flange ...

Page 1746: ... axle flange and remove the driveshaft 40 Index mark the transmission output shaft at the six o clock position 41 Remove the starter motor terminal cover 42 Disconnect the starter wiring 1 Remove the nut and disconnect the battery positive cable 2 Remove the nut and disconnect the starter solenoid wire ...

Page 1747: ...43 Remove the three bolts and the starter Automatic transmission vehicles 44 Remove the flywheel inspection cover 45 Remove the torque converter nuts All vehicles ...

Page 1748: ...nd the wiring harness bracket 47 Remove the nuts and position the wiring harness aside 48 Disconnect the oil pressure sensor 49 Remove the nut and the engine ground cable 50 Disconnect the hose from the oil filter adapter ...

Page 1749: ...or 52 NOTE Drain the power steering fluid into a suitable container Disconnect the hose from the power steering reservoir 53 Remove the bolt and the anti rotation clip 54 Loosen the fitting and disconnect the high pressure hose from the power steering pump ...

Page 1750: ...ound strap bolt 56 Remove the degas bottle support bracket 57 Install the two bolts from the RH lifting bracket 58 Disconnect the reversing lamp switch electrical connector and the wiring harness from the transmission ...

Page 1751: ...oxygen sensor electrical connectors from the crossmember Manual transmission vehicles 60 Remove the bolt and the clutch release lever cover 61 CAUTION To prevent component damage do not depress the clutch pedal with the transmission removed Detach the clutch release cable from the clutch release fork ...

Page 1752: ...tch cable retainer and remove the clutch cable from the transmission All vehicles 63 Position a transmission jack and support the transmission 64 Remove the transmission crossmember bolts Automatic transmission vehicles ...

Page 1753: ...n bolts and remove the transmission 67 NOTE RH side shown LH side similar Remove the two engine mount nuts 68 Remove the transmission wiring harness 1 Remove the RH oxygen sensor connector from the bracket 2 Disconnect the transmission wiring connector and remove the harness ...

Page 1754: ...he vehicle Manual transmission vehicles 70 Remove the two screws and position the clutch cable aside All vehicles 71 Attach the special tool to a floor crane and the engine and remove the engine from the vehicle ...

Page 1755: ......

Page 1756: ... A Remover Crankshaft Vibration Damper 303 009 T58P 6316 D Holding Tool Crankshaft 303 448 T93P 6303 A Guides Connecting Rod 303 442 T93P 6136 A Remover Crankshaft Rear Oil Seal 303 519 T95P 6701 EH Remover Crankshaft Rear Oil Slinger 303 514 T95P 6701 AH Compressor Valve Spring Intake 303 452 T93P 6565 AR Compressor Valve Spring Exhaust ...

Page 1757: ...on refer to Section 308 02 2 Remove the flywheel Automatic transmission vehicles 3 Remove the flexplate For additional information refer to Flexplate in this section All vehicles 4 Using the special tool remove the rear oil slinger 303 567 T97P 6565 AH Remover Crankshaft Front Oil Seal 303 107 T74P 6700 A ...

Page 1758: ...5 Using the special tool remove the rear main seal 6 Remove the rear seal retainer plate 7 Mount the engine on a work stand 8 Remove the special tools ...

Page 1759: ...positive crankcase ventilation PCV tube 10 Remove the PCV valve tube and electrical connector 11 Disconnect the exhaust gas recirculation EGR tube from the EGR valve 12 Disconnect the EGR tube from the exhaust manifold ...

Page 1760: ...isconnect the fuel pressure damper electrical connector 14 Disconnect the EGR vacuum regulator electrical connector 15 Disconnect the four LH fuel injector electrical connectors 16 Remove the LH coil cover ...

Page 1761: ...isconnect the generator 18 Disconnect the idle air control IAC valve electrical connector 19 Disconnect the throttle position TP sensor electrical connector 20 Remove the bolts and the upper intake manifold ...

Page 1762: ...21 Remove the upper intake manifold gasket Clean and inspect the sealing surfaces 22 Remove the RH coil cover 23 Disconnect the LH ignition coils ...

Page 1763: ...24 Disconnect the four RH fuel injector electrical connectors 25 Disconnect the engine coolant temperature ECT sensor 26 Disconnect the RH ignition coils 27 Remove the eight ignition coils ...

Page 1764: ...ve belt 30 Remove the coolant bypass tube and upper generator support bracket Remove the bolts Remove the coolant bypass tube Remove the upper generator support bracket 31 Remove the generator 32 Remove the eight bolts and the two studs in the sequence shown Remove the lower intake manifold ...

Page 1765: ...33 Remove the bolts and the coolant pump pulley 34 Remove the coolant pump from the cylinder block Remove the bolts Inspect and clean the sealing surfaces 35 Remove the bolt ...

Page 1766: ...36 Using the special tool remove the crankshaft pulley 37 Using the special tool remove the crankshaft front seal 38 Remove the belt idler pulleys 39 Remove the bolts and the LH valve cover ...

Page 1767: ...ess 1 LH knock sensor electrical connector 2 RH knock sensor electrical connector 3 Engine control sensor electrical connector 4 Fuel injector electrical connector 5 A C compressor electrical connector 6 Crankshaft position sensor CKP electrical connector 42 Remove the knock sensors ...

Page 1768: ...de is shown RH side is similar Remove the exhaust manifolds 1 Remove the nuts 2 Remove the LH and RH exhaust manifolds 3 Remove the exhaust manifold gaskets 44 Remove the four bolts 45 Remove the engine front cover ...

Page 1769: ... 53 6 W706508 Stud Hex Shldr Pilot M8 x 1 25 x 50 M6 x 1 x 10 7 N808586 Stud and Washer Hex Head Pilot M8 x 1 25 x 60 M6 x 1 x 26 8 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 9 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 10 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 11 N806300 Stud Hex Shldr Pilot M8 x 1 25 x 65 M8 x 1 25 x 26 12 W706560 Stud Hex Head Pilot M8 x 1 25 x 65 M8 x ...

Page 1770: ...Remove the CKP sensor pulse wheel 48 Using the special tool remove the 32 roller followers 49 Remove the bolts and the RH and LH timing chain tensioners 50 Remove the RH and LH timing chain tensioner arms ...

Page 1771: ...ains and crankshaft sprocket 52 Remove the RH and LH timing chain guides 53 Remove the RH and LH cylinder heads 54 Remove the oil filter adapter 1 Remove the oil filter 2 Remove the bolts 3 Remove the oil filter adapter 4 Remove the gasket ...

Page 1772: ...h the adapter with parts cleaner If metal particles are present install a new oil filter adapter 56 Remove the bolts and the oil pump screen and pickup tube 57 Remove the oil pump screen and pickup tube spacer 58 Remove the nuts and the windage tray ...

Page 1773: ...ts and the oil pump 62 CAUTION Do not stamp the top of pistons as ring land damage can occur NOTE Connecting rods and rod caps should be numbered to keep the correct orientation in the following sequence Remove the connecting rod caps for piston number 1 and 6 Discard the bolts ...

Page 1774: ...essary remove the ridge or carbon deposits from each cylinder using a cylinder ridge reamer following manufacturer s instructions Using the special tool push pistons number 1 and 6 through the top of the cylinder block 64 To remove pistons 3 and 5 4 and 7 2 and 8 turn crankshaft 90 degrees and repeat the previous two steps 65 Remove the side main bearing cap bolts ...

Page 1775: ...n bearing cap bolts 67 Remove the main bearing caps and the crankshaft lower main bearings from the cylinder block 68 Remove the crankshaft the crankshaft thrust washer and the crankshaft upper main bearings from the cylinder block ...

Page 1776: ......

Page 1777: ... into the same positions SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual Special Tool s Compressor Valve Spring Exhaust Side 303 567 T97P 6565 AH Compressor Valve Spring Intake Side 303 452 T93P 6565 AR Holding Tool Camshaft 303 446 T93P 6256 AHR Compressor Valve Spring Air Operated 134 R0207 or equivalent Installer Valve Stem Oil Seal 303 383 T91P 6571 A Material Item Specifica...

Page 1778: ...al tool 2 Remove the exhaust camshaft sprocket and the intake camshaft bolt washer and spacer 3 Compress the tensioner and install a lock pin 4 Remove the special tool 5 Remove the timing chain and the camshaft sprocket ...

Page 1779: ... the tensioner 7 Remove the roller followers on the base circle 1 Install the special tool on the valve spring 2 Compress the tool and remove the roller follower 8 Repeat the previous step for the remaining roller followers 9 Remove the hydraulic lash adjusters ...

Page 1780: ...using damage to the cylinder head Install the air operated spring compressor on the cylinder head 11 Compress the valve spring compressor and remove the key from the valves 12 Remove the intake valves and the valve springs 1 Release the pressure and remove the valve spring compressor 2 Remove the intake valves and the valve springs from the cylinder head ...

Page 1781: ...s on the outer cam bearing cap exhaust are longer and must be returned to the same location or engine damage may occur NOTE Identify the camshaft to cylinder head location Caps are not interchangeable Remove the bolts and the camshaft bearing cap assemblies ...

Page 1782: ...valves and the valve springs 3 CAUTION Make sure the tool is seated correctly on the valve spring Apply a small amount of air at a time This will prevent the tool from shifting and causing damage to the cylinder head Install the air operated spring compressor on the cylinder head ...

Page 1783: ...s the valve spring compressor and install the key on the valves 5 NOTE LH is shown RH is similar Install the camshafts Lubricate the camshafts with clean engine oil 6 Install the camshaft bearing cap assemblies ...

Page 1784: ...nstall the roller followers 1 Install the special tool on the valve spring 2 Compress the spring and install the roller follower 9 Repeat the previous step for the remaining roller followers 10 NOTE LH tensioner is shown RH tensioner is similar ...

Page 1785: ...AUTION Timing marks must be at 12 o clock and indexed at 6 o clock Install the camshaft sprockets and the chain as an assembly 12 Install the special tool 13 Install the camshaft spacer washer and bolt and hand tighten the bolt ...

Page 1786: ...stall the camshaft sprocket washer and bolt and hand tighten the bolt 15 Tighten the bolts in two stages Stage 1 Tighten to 40 Nm 30 lb ft Stage 2 Tighten and additional 90 degrees 16 Remove the special tool ...

Page 1787: ......

Page 1788: ...1 Remove the clips 2 Remove the piston pin from the piston and connecting rod assembly 3 Remove the connecting rod from the piston SECTION 303 01D Engine Mach I 4 6L 4V 2003 Mustang Workshop Manual Material Item Specification SAE 5W 20 Premium Synthetic Blend Engine Oil XO 5W20 QSP WSS M2C153 H ...

Page 1789: ...Section 303 00 Assembly 1 NOTE Connecting rod must be installed into piston with identification markings toward front Position the connecting rod in the piston 2 Lubricate the piston pin and pin bore with clean engine oil 3 Install the piston pin in the piston and connecting rod assembly ...

Page 1790: ...4 Install the piston pin retaining clips in the piston ...

Page 1791: ...rankshaft Vibration Damper 303 102 T74P 6316 B Installer Front Cover Oil Seal 303 335 T88T 6701 A Installer Crankshaft Rear Oil Seal 303 518 T95P 6701 DH Installer Crankshaft Rear Oil Slinger 303 517 T95P 6701 CH Compressor Valve Spring Intake 303 452 T93P 6565 AR Compressor Valve Spring Exhaust 303 567 T97P 6565 AH Installer Crankshaft Rear Oil Seal ...

Page 1792: ...303 D032 D81L 6002 C or equivalent Holding Tool Crankshaft 303 448 T93P 6303 A Material Item Specification Metal Surface Cleaner F4AZ 19A536 RA or equivalent WSE M5B392 A Silicone Gasket and Sealant F7AZ 19554 EA or equivalent WSE M4G323 A4 Super Premium SAE 5W 20 Engine Oil XO 5W20 QSP or equivalent WSS M2C153 H Motorcraft Premium Gold Engine Coolant VC 7 A in Oregon VC 7 B yellow color WSS M97B5...

Page 1793: ...oss the row next to the crankshaft main bearing code letter until the two intersect This is the required bearing grade for the number one crankshaft main bearing As an example if the engine block code letter is F and the crankshaft code letter is D the correct bearing grade for this main bearing is 2 Repeat this process for the remaining four main bearings 4 If oversize bearings are being used use...

Page 1794: ...o the cylinder block and the lower main bearing into the crankshaft main bearing caps Lubricate the main bearings with clean engine oil 6 Install the crankshaft into the cylinder block 7 CAUTION Make sure the coated side of the thrust washer with the 5 mm wide oil grooves faces the crankshaft thrust surface Push the crankshaft rearward and install the crankshaft thrust washer at the back of the No...

Page 1795: ...he crankshaft forward to seat the crankshaft thrust washer and hold the crankshaft in the forward position 10 Tighten bolts 1 20 in sequence shown in four stages Stage 1 tighten to 10 Nm 89 lb in Stage 2 tighten to 25 Nm 18 lb ft Stage 3 tighten to 40 Nm 30 lb ft ...

Page 1796: ... 90 degrees 11 Install and tighten the cross mounted bolts in two stages Stage 1 tighten to 40 Nm 30 lb ft Stage 2 tighten an additional 90 degrees 12 Check the crankshaft end play For additional information refer to Section 303 00 ...

Page 1797: ...the cylinder block 14 CAUTION Do not scratch the cylinder walls or the crankshaft journals with the connecting rod NOTE Make sure the crankshaft is at T D C Using the special tool install the connecting rod assemblies 15 NOTE The rod bearing cap bolts are torque to yield Install new bolts each time they are serviced Install the connecting rod bearing caps and bolts and tighten in three stages Stag...

Page 1798: ...rod bearing clearance For additional information refer to Section 303 00 17 Install the LH engine mount 18 Install the RH engine mount 19 Install the nuts and the windage tray 20 Install and tighten the oil pump screen spacer ...

Page 1799: ...stall a new O ring if necessary Install the oil pump screen cover and tube 23 Install the cylinder head gaskets 24 CAUTION The camshafts must be positioned so the camshaft keyway is 90 degrees from the valve cover gasket surface to avoid damage to valves and pistons during timing ...

Page 1800: ...e bolts in six stages in the sequence shown Stage 1 tighten to 40 Nm 30 lb ft Stage 2 tighten an additional 90 degrees Stage 3 loosen the bolts a minimum of one full turn Stage 4 tighten to 40 Nm 30 lb ft Stage 5 tighten an additional 90 degrees Stage 6 tighten an additional 90 degrees 26 CAUTION Timing chain procedures must be followed exactly or damage to valves and pistons will result Compress ...

Page 1801: ...28 Remove the tensioner from the vise 29 If the copper links are not visible mark two links on one end and one link on the other end and use as timing marks 30 Install the timing chain guides 31 Rotate the LH camshaft timing sprocket until the timing mark is approximately at the 12 o clock ...

Page 1802: ...evere piston and valve damage will occur CAUTION Rotate the crankshaft counterclockwise only Do not rotate past position shown or severe piston and or valve damage will occur Using the special tool position the crankshaft Remove the special tool 33 Install the crankshaft sprocket with the flange facing forward 34 Install the LH and RH timing chain onto the crankshaft sprocket aligning the one copp...

Page 1803: ...ke sure the two copper colored links align with the camshaft sprocket timing mark 36 As a post check verify correct alignment of all timing marks 37 Position the LH and RH timing chain tensioner arms on the dowel pins Position the timing chain tensioner assemblies and install the bolts 38 Remove the retaining clips from the timing chain tensioners ...

Page 1804: ...aft sensor ring on the crankshaft 40 Install the oil pan and gasket and loosely install the bolts 41 Tighten the bolts in the sequence shown Tighten to 20 Nm 15 lb ft Rotate an additional 60 degrees 42 Install the drain plugs ...

Page 1805: ...ng area cleaned with metal surface cleaner Allow to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure can result in future oil leakage Apply silicone gasket and sealant in the locations shown 44 Install the engine front cover Item Part Number Description ...

Page 1806: ...lange Head Pilot M8 x 1 25 x 53 5 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 6 W706508 Stud Hex Shldr Pilot M8 x 1 25 x 50 M6 x 1 x 10 7 N808586 Stud and Washer Hex Head Pilot M8 x 1 25 x 60 M6 x 1 x 26 8 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 9 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 10 N806177 Bolt Hex Flange Head Pilot M8 x 1 25 x 53 11 N806300 Stud Hex Shldr Pilot M...

Page 1807: ...ling area cleaned with metal surface cleaner Allow to dry until there is no sign of wetness or four minutes whichever is longer Failure to follow this procedure can result in future oil leakage Apply silicone gasket and sealant in the locations shown 49 NOTE The RH is shown the LH is similar Install the valve covers and tighten the bolts in the sequence shown ...

Page 1808: ...50 Install the belt idler pulleys 51 Lubricate the front oil seal and the engine front cover with clean engine oil 52 Using the special tool install the front oil seal ...

Page 1809: ...ulley 54 Using the special tool install the crankshaft pulley 55 Install the crankshaft pulley and tighten the bolt in four stages Stage 1 tighten to 90 Nm 66 lb ft Stage 2 loosen the bolt one full turn Stage 3 tighten to 50 Nm 37 lb ft Stage 4 tighten an additional 90 degrees ...

Page 1810: ...e the O ring seal with clean engine oil Install the coolant pump 57 NOTE The RH is shown the LH is similar Use new gaskets when installing the exhaust manifolds Install the exhaust manifold 58 Install the knock sensors ...

Page 1811: ...nector 3 Engine control sensor electrical connector 4 Fuel injector electrical connector 5 A C compressor electrical connector 6 CKP sensor electrical connector 60 Install the lower intake manifold Position the gaskets Install the intake manifold and tighten the bolts in the sequence shown 61 Install the generator ...

Page 1812: ...per generator support bracket and coolant bypass tube Install the upper generator support bracket Install the coolant bypass tube Install the bolts 63 Install the eight ignition coils 64 Connect the eight ignition coils ...

Page 1813: ...nect the engine coolant temperature ECT sensor 66 Connect the eight fuel injectors 67 Install the RH ignition coil cover 68 NOTE The fastener at location five is a stud Install the gasket and the upper intake ...

Page 1814: ...69 Connect the throttle position TP sensor electrical connector 70 Connect the idle air control IAC valve electrical connector 71 Connect the generator wiring ...

Page 1815: ...72 Install the LH coil cover 73 Connect the EGR vacuum regulator EVR electrical connector 74 Connect the fuel pressure sensor electrical connector 75 Connect the EGR tube to the exhaust manifold ...

Page 1816: ...76 Connect the EGR tube to the EGR valve 77 Install the PCV valve hose and connect the electical connector 78 Connect the PCV valve tube to the upper intake manifold 79 Install the special tool ...

Page 1817: ...oil leakage Apply a 4 mm 0 16 in bead of silicone gasket and sealant around the rear oil seal retainer plate sealing surface Also apply a bead of silicone gasket and sealant at the junction where the cylinder block oil pan and rear oil seal retainer plate meet 82 Install the rear oil seal retainer plate Tighten the bolts in the sequence shown Tighten the bolts to 1 6 to 10 Nm 89 lb in Hand tighten...

Page 1818: ... special tool install the crankshaft rear main seal 84 Using the special tools install the crankshaft oil slinger Automatic transmission vehicles 85 Install the flexplate and install the bolts in the sequence shown ...

Page 1819: ...Manual transmission vehicles 86 Install the flywheel and the bolts in the sequence shown 87 Install the clutch and pressure plate For additional information refer to Section 308 02 ...

Page 1820: ......

Page 1821: ...et Engine 303 D087 D93P 6001 A1 Lifting Bracket Engine 303 D088 D93P 6001 A2 Installer Set Teflon Seal 211 D027 D90P 3517A or equivalent Spreader Bar 303 D089 D93P 6001 A3 or equivalent Material Item Specification Super Premium SAE 5W 20 Engine Oil XO 5W20 QSP or equivalent WSS M2C153 H Motorcraft Premium Gold Engine Coolant VC 7 A in Oregon VC 7 B yellow color WSS M97B51 A1 Threadlock and Sealer ...

Page 1822: ...and support the vehicle For additional information refer to Section 100 02 4 Connect the transmission wiring harness 1 Connect the RH oxygen sensor connector retainer 2 Connect the transmission harness electrical connector 5 NOTE RH side shown LH side similar Install the LH and RH engine mount nuts ...

Page 1823: ...anual transmission vehicles 6 Lubricate the ball stud clutch release lever and the input shaft with clean engine oil All vehicles 7 Raise the transmission and install the seven bolts 8 Install the bolts ...

Page 1824: ...ansmission crossmember and the bolts 10 Remove the transmission jack Manual transmission vehicles 11 Install the clutch cable and the clutch cable retainer 12 Attach the clutch release cable to the clutch release fork ...

Page 1825: ...ut shaft speed OSS sensor electrical connector and attach the left and right oxygen sensor electrical connectors to the crossmember 15 Connect the reversing lamp switch electrical connector and the wiring harness to the transmission 16 Remove the two bolts from the RH lifting bracket ...

Page 1826: ...17 Install the degas bottle support bracket 18 Connect the engine ground strap to the frame 19 Using the special tool install a new seal ring 20 Install the high pressure power steering hose to the pump ...

Page 1827: ...21 Position the clip and install the bolt 22 Connect the hose to the power steering reservoir 23 Connect the lower radiator hose 24 Connect the hose to the oil filter adapter ...

Page 1828: ...25 Install the ground cable 26 Connect the oil pressure sender 27 Position the wiring harness and install the two nuts 28 Position the wiring harness bracket and install the nut ...

Page 1829: ... the starter and install the bolts 30 Install the starter wires 1 Position the solenoid wire and install the nut 2 Position the battery cable and install the nut 31 Install the cap Automatic transmission vehicles ...

Page 1830: ...If new bolts are not available apply threadlock to the threads of the original bolts CAUTION The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot To make sure the yoke seats squarely on the flange tighten the bolts evenly in the sequence shown NOTE Align the marks made on the flange and driveshaft during removal Position the driveshaft and install the driveshaft t...

Page 1831: ...ll the bracket nut 37 Install the dual converter H pipe For additional information refer to Section 309 00 38 Lower the vehicle 39 Install the shifter For additional information refer to Section 307 01 or Section 308 03B 40 Install the degas bottle 41 Connect the degas bottle return hose ...

Page 1832: ...42 Connect the radiator vent hose to the degas bottle 43 Remove the LH lifting bracket 44 Remove the RH lifting bracket 45 Connect the A C tube ...

Page 1833: ...46 Connect the A C suction tube to the manifold tube 47 Connect the A C suction tube to the accumulator 48 Connect the hose to the bypass tube 49 Connect the cables ...

Page 1834: ...50 Connect the connectors 51 Position the wiring support bracket and install the nuts 52 Connect the heater hoses 53 Connect the vacuum hoses ...

Page 1835: ...54 Connect the fuel charging wiring harness 55 Connect the 16 pin and the 42 pin connectors 56 Connect the evaporative emissions return tube 57 Position the cables and install the bolts ...

Page 1836: ... control actuator cable and install the throttle return spring 59 Install the upper radiator hose 60 Connect the wiring connector 61 Install the air cleaner assembly 1 Install the air cleaner and the outlet tube as an assembly 2 Install the bolt ...

Page 1837: ...nector 63 Connect the air cleaner outlet pipe at the throttle body 1 Connect the positive crankcase ventilation PCV inlet tube 2 Tighten the clamp 64 NOTE Use reference marks made during removal to aid in the installation Install the hood and the four nuts ...

Page 1838: ...ation refer to Section 414 01 69 Fill the crankcase with clean engine oil and check that all other fluids are at the correct levels 70 Fill and bleed the engine cooling system For additional information refer to Section 303 03A 71 Fill and purge the power steering system For additional information refer to Section 211 00 72 Start the engine and check for leaks Stop the engine and recheck the fluid...

Page 1839: ...or Cap Pressure Test Specifications 110 kPa 16 psi Thermostat Opening Temperatures Starts to open 4 6L 2V 87 93 C 192 199 F Starts to open 3 8L 86 7 90 6 C 189 196 F Starts to open Cobra 80 83 C 175 182 F Fully open 104 C 219 F Torque Specifications Description Nm lb ft lb in Accelerator cable bracket bolts 10 89 Cylinder block drain plug 20 15 Exhaust manifold to EGR valve tube nut 35 26 Fan shro...

Page 1840: ... 4 6L 2V 25 18 Coolant outlet connection bolts 4 6L 4V 10 89 Coolant pump bolts 3 8L 28 21 Coolant pump bolts 4 6L 25 18 Coolant pump pulley bolts 25 18 Air intake scoop bolts 25 18 Air intake scoop bracket bolt 25 18 Air intake scoop bracket nuts 25 18 Air intake scoop bracket throttle body nut 9 80 Exhaust gas recirculation EGR vacuum regulator solenoid bolts 10 89 ...

Page 1841: ...r fan blade fan motor and fan shroud assembly radiator pressure relief cap radiator draincock coolant pump coolant thermostat oil filter adapter radiator overflow hose upper radiator hose lower radiator hose The radiator overflow hose circulates the coolant The coolant thermostat controls the engine coolant temperature allows for quicker engine warm up The degas bottle coolant expansion tank provi...

Page 1842: ... coolant pump An open coolant thermostat allows the engine coolant to flow to the radiator CAUTION Engine coolant provides freeze protection boil protection cooling efficiency and corrosion protection to the engine and cooling components In order to obtain these protections the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle 4 6L or coolant expans...

Page 1843: ...ss it meets the requirements of Ford specification WSS M97B51 A1 Not all coolant recycling processes meet these Ford specifications Use of such coolants can harm the engine and cooling system components The coolant temperature sensor 4 6L or cylinder head temperature sensor 3 8L provides a signal to the temperature gauge The optional block heater electrical heating element is installed in the core...

Page 1844: ...een released turn and remove the pressure relief cap still with a cloth CAUTION Check the coolant level engine oil and transmission fluid top off the coolant if needed If there is engine coolant in the engine oil or transmission fluid the cause must be corrected and oil fluid changed or major component damage may occur 1 Verify the customer s concern by operating the engine to duplicate the condit...

Page 1845: ...nd engine coolant An iridescent sheen on top of the coolant can indicate a trace of oil is entering the system For additional information on engine diagnosis refer to Section 303 00 A milky brown color may indicate that either engine oil or transmission fluid is entering the cooling system If transmission fluid is suspected the cause may be a leaky radiator Pressure test the cooling system For add...

Page 1846: ...Go To Pinpoint Test A The engine overheats Thermostat Coolant pump Internal engine coolant leak Radiator Cooling fan Pressure relief cap or radiator cap Go To Pinpoint Test B The engine does not reach normal operating temperature Thermostat Go To Pinpoint Test C Test Step Result Action to Take A1 CHECK THE ENGINE COOLANT LEVEL WARNING Never remove the pressure relief cap while the engine is operat...

Page 1847: ... degas bottle coolant expansion tank for signs of transmission fluid or engine oil Is oil or transmission fluid evident in the coolant Yes If engine oil is evident REFER to Section 303 00 If transmission fluid is evident REPAIR or INSTALL a new radiator as necessary No GO to A4 A4 CHECK THE ENGINE AND THE TRANSMISSION FOR COOLANT Remove the oil level dipstick from the engine and the transmission I...

Page 1848: ...ansion tank Is the engine coolant OK Yes GO to B2 No REFILL the engine coolant at the degas bottle coolant expansion tank Go To Pinpoint Test A B2 CHECK THE COOLANT CONDITION Check the coolant for dirt rust or contamination Is the coolant condition OK Yes GO to B3 No FLUSH the engine cooling system REFER to Engine and Radiator Flushing in this section TEST the system for normal operation B3 CHECK ...

Page 1849: ...er 2 CAUTION Do not pressurize the cooling system beyond 110 kPa 16 psi Pump the cooling system to a maximum of 102 kPa 14 9 psi and hold for 2 minutes If the pressure drops within this time inspect for leaks and repair as necessary Pressure Test 4 6L B5 CHECK THE COOLING FAN OPERATION Carry out the cooling fan component tests Go to Component Tests Is the cooling fan operation OK Yes For diagnosis...

Page 1850: ... cap in clean water to dislodge all foreign particles from the gaskets Check the sealing surface in the filler neck 6 If 110 kPa 16 psi cannot be reached install a new pressure relief cap If more than 124 kPa 18 psi shows on gauge install a new pressure relief cap 7 CAUTION If the pressure drops check for leaks at the engine to heater core hoses engine to radiator hoses water valve hose if applica...

Page 1851: ...ressure reading obtained 4 If the pressure test gauge readings are not within specifications install a new pressure relief cap If the pressure test gauge readings are within specifications carry out the cooling system Pressure Test Thermostat Water A new water thermostat should be installed only after the following electrical and mechanical tests have been carried out Thermostat Electrical Test CA...

Page 1852: ...GO to Symptom Chart for further instructions Thermostat Mechanical Test 1 Remove the water thermostat 2 Check the water thermostat for seating Hold the water thermostat up to a lighted background Leakage of light around the thermostat valve at room temperature indicates that a new water thermostat should be installed Some water thermostats have a small leakage notch at one location on the perimete...

Page 1853: ...1 Leak test the radiator in clean water with 138 kPa 20 psi air pressure Fan Electric Test Refer to the Powertrain Control Emissions Diagnosis PC ED manual ...

Page 1854: ... by slowly turning the pressure relief cap one half turn counterclockwise or the radiator cap counterclockwise to the first stop When the pressure is released remove the pressure relief cap radiator cap 2 Place a suitable container below the radiator draincock If equipped disconnect the coolant return hose at the fluid cooler Open the draincock and drain the engine coolant Close the radiator drain...

Page 1855: ...em components NOTE The addition of Motorcraft Cooling System Stop Leak Pellets VC 6 darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan 1 Place the heater temperature selector in the maximum cool position 2 CAUTION On 3 8L engines the vent plug must be removed before radiator fill or the engine may not fill completely NOTE It is important to maintain engine coolant concentrate...

Page 1856: ...lants may degrade the coolant s corrosion protection Do not add alcohol methanol or brine or any engine coolants mixed with alcohol or methanol antifreeze These can cause engine damage from overheating or freezing Do not mix with recycled coolant unless it meets the requirements of Ford specification WSS M97B51 A1 Not all coolant recycling processes meet these Ford specifications Use of such coola...

Page 1857: ...nd cooling components In order to obtain these protections the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle When adding engine coolant use a 50 50 mixture of engine coolant and deionized water To maintain the integrity of the coolant and the cooling system Add Motorcraft Premium Gold Engine Coolant VC 7 A in Oregon VC 7 B or equivalent meeting ...

Page 1858: ...ined Run the engine until the thermostat opens coolant flowing through the radiator lower hose becomes hot 9 Stop the engine and allow to cool 10 Add coolant to the engine crossover tube fill neck until the cooling system is full 11 Install the fill plug 12 Repeat the fill procedure if necessary Filling Mach I CAUTION Vehicle cooling systems are filled with Motorcraft Premium Gold Engine Coolant V...

Page 1859: ...ressure cap from the cooling system reservoir and the fill plug from the engine crossover tube 5 CAUTION Do not fill the cooling system through the reservoir only Coolant will not enter the engine Only the reservoir and the radiator will be filled and engine overheating will occur Add coolant into the fill neck on the engine crossover tube until coolant reaches the top of the fill neck on the cool...

Page 1860: ...gauge does not move the engine coolant level is low and must be filled Stop the engine allow the engine to cool and fill cooling system Start the engine and allow it to idle until normal operating temperature is reached Hot air should discharge from A C vents The engine coolant temperature gauge should maintain a stabilized reading in the middle of the NORMAL range The upper radiator hose should f...

Page 1861: ...een released turn and remove the pressure relief cap still with a cloth Once pressure is released remove the pressure relief cap radiator cap 2 Drain the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section 3 Remove the coolant thermostat For additional information refer to Thermostat 3 8L Thermostat 4 6L 2V or Thermostat 4 6L 4V in this s...

Page 1862: ... engine and radiator Use Ford Premium Cooling System Flush VC 1 or equivalent meeting Ford specification ESR M14P7 A Always flush the cooling system with water thoroughly after using the VC 1 flush and prior to filling the cooling system with the same coolant that was present in the system Do not mix coolant types 6 Install the thermostat 7 Backflush the heater core For additional information refe...

Page 1863: ...m For additional information refer to Cooling System Draining Filling and Bleeding in this section 3 NOTE For additional information refer to the cooling system flusher manufacturer s operating instructions for particular vehicle hook up Use an appropriate cooling system flusher to backflush the heater core Use Motorcraft Cooling System Flush VC 1 or equivalent meeting Ford specification ESR M14P7...

Page 1864: ......

Page 1865: ...oolant hose connection 3 Remove the thermostat housing Remove the bolts 4 Remove the thermostat Clean and inspect the water outlet connection Discard the thermostat gasket and clean and inspect the mating surface SECTION 303 03A Engine Cooling 2003 Mustang Workshop Manual Material Item Specification Gasket Adhesive TA 6 or equivalent WSS M2G408 A Motorcraft Premium Gold Engine Coolant VC 7 A in Or...

Page 1866: ...ed to the original location NOTE Coat the new thermostat gasket with gasket adhesive NOTE Make sure the new O ring gasket is secure around the thermostat To install reverse the removal procedure 7 Fill the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section ...

Page 1867: ......

Page 1868: ...s and coolant outlet connection 3 Position aside the coolant outlet connection and the upper radiator hose 4 Remove the thermostat and O ring seal from the upper intake manifold Inspect the O ring seal Install a new seal if necessary SECTION 303 03A Engine Cooling 2003 Mustang Workshop Manual Material Item Specification Motorcraft Premium Gold Engine Coolant VC 7 A in Oregon VC 7 B yellow color WS...

Page 1869: ...5 To install reverse the removal procedure ...

Page 1870: ...ostat housing bolts 4 Remove the coolant thermostat 1 Separate the thermostat housing 2 Remove the coolant thermostat and the O ring seal Inspect the O ring seal Install a new seal if necessary 5 NOTE The thermostat is indexed and must be returned to the original location NOTE Make sure the new O ring seal is secure around the thermostat SECTION 303 03A Engine Cooling 2003 Mustang Workshop Manual ...

Page 1871: ...To install reverse the removal procedure 6 Fill the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section ...

Page 1872: ...or additional information refer to Section 303 01A 3 Remove the bypass hose from the bypass tube 4 Remove the bolt and remove the bypass tube from the coolant pump 5 Disconnect the quick connect fitting and remove the bracket bolts and the bypass tube SECTION 303 03A Engine Cooling 2003 Mustang Workshop Manual Material Item Specification Motorcraft Premium Gold Engine Coolant VC 7 A in Oregon VC 7...

Page 1873: ...e 7 CAUTION Do not cut the O ring seal during tube installation or engine coolant leakage may occur Clean the O ring sealing surface on the cylinder heads and lubricate the O ring seal Use premium engine coolant 8 To install reverse the removal procedure ...

Page 1874: ......

Page 1875: ...ower hose 3 Remove the supercharger belt For additional information refer to Section 303 05 4 Disconnect the engine coolant temperature sensor electrical connector and unclip the wiring harness from the stud 5 NOTE LH is shown RH is similar Remove the coolant bypass nuts SECTION 303 03A Engine Cooling 2003 Mustang Workshop Manual Material Item Specification Motorcraft Premium Gold Engine Coolant V...

Page 1876: ... tube 7 NOTE Install new bypass tube O rings and lubricate them using premium engine coolant To install reverse the removal procedure 8 Fill and bleed the engine cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section ...

Page 1877: ...refer to Cooling System Draining Filling and Bleeding in this section 3 Disconnect the upper radiator hose from the bypass tube 4 Disconnect the lower radiator hose 5 Disconnect the engine temperature control ECT sensor electrical connector SECTION 303 03A Engine Cooling 2003 Mustang Workshop Manual Material Item Specification Motorcraft Premium Gold Engine Coolant VC 7 A in Oregon VC 7 B yellow c...

Page 1878: ...lant leakage may occur NOTE Wipe the O ring sealing surface on the cylinder heads with a soft cloth if necessary and lubricate the O ring seal Use premium engine coolant To install reverse the removal procedure 8 Fill the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section ...

Page 1879: ......

Page 1880: ...Remove the power steering PS pump pulley For additional information refer to Section 211 02 4 Remove the bolts and the coolant pump pulley 5 Remove the PS bracket Remove the bolts Remove the nuts 6 Disconnect the lower radiator hose from the coolant pump SECTION 303 03A Engine Cooling 2003 Mustang Workshop Manual Material Item Specification Motorcraft Premium Gold Engine Coolant VC 7 A in Oregon V...

Page 1881: ...Position aside the coolant heater outlet tube assembly Remove the bolt 8 Remove the coolant pump Remove the stud Remove the four bolts Remove the four nuts 9 Clean and inspect the gasket sealing surfaces ...

Page 1882: ...l procedure Install a new gasket Tighten the coolant pump stud bolts and nuts in the sequence shown 11 Fill and bleed the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section ...

Page 1883: ...303 12 Cobra 2 Remove the supercharger drive belt cover 3 Rotate the supercharger belt tensioner clockwise and remove the supercharger drive belt 4 Remove the coolant hose mounting bolt SECTION 303 03A Engine Cooling 2003 Mustang Workshop Manual Material Item Specification Motorcraft Premium Gold Engine Coolant VC 7 A in Oregon VC 7 B yellow color WSS M97B51 A1 ...

Page 1884: ...ine coolant For additional information refer to Cooling System Draining Filling and Bleeding in this section 7 Loosen the coolant pump pulley bolts 8 Remove the accessory drive belt For additional information refer to Section 303 05 9 Remove the bolts and the coolant pump pulley ...

Page 1885: ...2 CAUTION Do not rotate the coolant pump housing once installed in the engine Damage to the O ring seal can occur causing the coolant pump to leak NOTE Install a new O ring seal and lubricate with the same clean engine coolant that is present in the system Do not mix coolant types To install reverse the removal procedure ...

Page 1886: ......

Page 1887: ...ystem For additional information refer to Cooling System Draining Filling and Bleeding in this section 3 Remove the radiator sight shield Release the clips 4 Remove the fan blade fan motor and fan shroud assembly For additional information refer to Cooling Fan Motor and Shroud in this section 5 Remove the upper radiator hose from the radiator SECTION 303 03A Engine Cooling 2003 Mustang Workshop Ma...

Page 1888: ...backup wrench If equipped remove the transmission lower cooler tube fitting 7 NOTE To avoid disturbing the transmission oil cooler fittings use a backup wrench If equipped remove the upper transmission cooler tube fitting 8 Remove the lower radiator hose from the radiator ...

Page 1889: ...install reverse the removal procedure 12 Fill and bleed the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section Mach I 13 Install the air intake scoop For additional information refer to Section 303 12 ...

Page 1890: ......

Page 1891: ...ve the degas bottle or coolant expansion tank For additional information refer to Degas Bottle 4 6L 2V and 4 6L 4V in this section 3 Disconnect the cooling fan electrical connector 4 Separate the fan harness from the shroud 5 Remove the LH bolt 6 Remove the RH bolt SECTION 303 03A Engine Cooling 2003 Mustang Workshop Manual ...

Page 1892: ...7 Remove the fan motor and shroud 8 To install reverse the removal procedure ...

Page 1893: ...efer to Cooling System Draining Filling and Bleeding in this section 2 Remove the bypass hose 3 To install reverse the removal procedure 4 Fill and bleed the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section SECTION 303 03A Engine Cooling 2003 Mustang Workshop Manual ...

Page 1894: ...aining Filling and Bleeding in this section 2 Disconnect the radiator vent hose 3 Remove the degas bottle return hose 4 Remove the nuts and the degas bottle 5 To install reverse the removal procedure 6 Fill and bleed the cooling system For additional information refer to Cooling System Draining Filling and Bleeding in this section SECTION 303 03A Engine Cooling 2003 Mustang Workshop Manual ...

Page 1895: ......

Page 1896: ...C 5 in Oregon a ESE M97B44 A Motorcraft Premium Gold Engine Coolant VC 7 A in Oregon VC 7 B a b WSS M97B51 A1 Other Chemicals Premium Cooling System Flush VC 1 ESR M14P7 A Premium Long Life Grease XG 1 C ESA M1C75 B Cooling System Stop Leak Pellets VC 6 ESE M99B37 5 except as noted in ES F65E 19A511 AA Cooling System Pressure Test Specifications System radiator kPa psi 138 20 System intercooler kP...

Page 1897: ......

Page 1898: ...se patents The cooling system components include the intercooler intercooler radiator 8K226 pressure relief cap degas bottle electric water pump 8501 The degas bottle provides a location for system fill contains coolant expansion and system pressurization provides air separation during operation replenishes the intercooler coolant to the system The intercooler coolant flows from the intercooler to...

Page 1899: ... cooling system Do not mix coolant types Do not add mix orange colored Motorcraft Speciality Orange Engine Coolant VC 2 or equivalent meeting Ford specification WSS M97B44 D Mixing coolants may degrade the coolant s corrosion protection Do not add alcohol methanol brine or any engine coolants mixed with alcohol or methanol antifreeze These can cause engine damage from overheating or freezing Do no...

Page 1900: ... you are sure all the pressure has been released still with a cloth turn and remove the pressure relief cap CAUTION Check the coolant and engine oil levels Top off the coolant level if needed If there is engine coolant in the engine oil the cause must be corrected and the oil changed or major component damage can occur SECTION 303 03B Supercharger Cooling 2003 Mustang Workshop Manual Special Tool ...

Page 1901: ...the pressure relief cap wait until the engine has cooled then wrap a thick cloth around the pressure relief cap and turn it slowly Step back while the pressure is released from the cooling system When you are sure all the pressure has been released still with a cloth turn and remove the pressure relief cap Allow the engine to cool Once pressure is released remove the pressure relief cap 2 CAUTION ...

Page 1902: ...pearance is acceptable test the engine coolant freezing point range with the special tool The freezing point should be in the range 50 F to 10 F If the vehicle is driven in cold climates less than 34 F it may be necessary to increase the coolant concentration to get adequate freeze protection Maximum coolant concentration is 60 40 Minimum coolant concentration is 40 60 4 Check the coolant system c...

Page 1903: ...degas bottle Wait until the engine has cooled then wrap a thick cloth around the pressure relief cap and turn it slowly one turn counterclockwise Step back while the pressure is released from the cooling system When certain all the pressure has been released remove the pressure relief cap still with a cloth Remove the pressure relief cap Inspect the pressure relief cap for foreign material between...

Page 1904: ...g obtained 5 If the pressure relief cap does not hold pressure remove and wash the pressure relief cap in clean water to dislodge all foreign particles from the gaskets Check the sealing surface in the filler neck 6 If 69 kPa 10 psi cannot be reached install a new pressure relief cap If more than 12 kPa 18 psi shows on the gauge install a new pressure relief cap 7 CAUTION If the pressure drops che...

Page 1905: ...to the male quick connect fitting of the filler neck adapter 5 NOTE If the plunger of the pump is depressed too fast an erroneous pressure reading will result Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops increasing and note the highest pressure reading obtained 6 Release the pressure by turning the relief screw counterclockwise Then tighten the pressu...

Page 1906: ......

Page 1907: ...OTE The addition of Motorcraft Cooling System Stop Leak Pellets VC 6 darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan NOTE Less than 80 of coolant capacity can be recovered with the engine in the vehicle Dirty rusty or contaminated coolant requires replacement 1 Raise and support the vehicle For additional information refer to Section 100 02 2 Remove the lower hose from the...

Page 1908: ...ing processes meet these Ford specifications Use of such coolants can harm the engine and cooling system components 2 Fill the degas bottle Use Motorcraft Premium Engine Coolant VC 4 A in Oregon VC 5 in Canada CXC 10 or equivalent meeting Ford specification ESE M97B44 A green color or Motorcraft Premium Gold Engine Coolant VC 7 A or equivalent meeting Ford specification WSS M97B51 A1 yellow color ...

Page 1909: ...ou are sure all the pressure has been released still with a cloth turn and remove the pressure relief cap Once pressure is released remove the pressure relief cap 2 Drain the cooling system For additional information refer to Supercharger Cooling System Draining Filling and Bleeding in this section 3 NOTE Refer to the cooling system flusher manufacturer s operating instructions for specific vehicl...

Page 1910: ......

Page 1911: ...ormation refer to Supercharger Cooling System Draining Filling and Bleeding in this section 3 Remove the retainer and position the inner fender well aside 4 Disconnect the water pump electrical connector 5 Disconnect the coolant hoses 6 Remove the bolts and the water pump SECTION 303 03B Supercharger Cooling 2003 Mustang Workshop Manual ...

Page 1912: ...7 To install reverse the removal procedure ...

Page 1913: ...mation refer to Supercharger Cooling System Draining Filling and Bleeding in this section 2 NOTE RH is shown LH is similar Disconnect the two coolant hoses 3 Remove the bolts and the radiator 4 To install reverse the removal procedure SECTION 303 03B Supercharger Cooling 2003 Mustang Workshop Manual ...

Page 1914: ......

Page 1915: ...r additional information refer to Supercharger Cooling System Draining Filling and Bleeding in this section 2 Disconnect the coolant hoses 3 Remove the bolts and the degas bottle 4 To install reverse the removal procedure SECTION 303 03B Supercharger Cooling 2003 Mustang Workshop Manual ...

Page 1916: ......

Page 1917: ...Specifications Item Specification Lubricants and Chemicals SAE 5W 20 Premium Synthetic Blend Motor Oil XO 5W20 QSP WSS M2C153 H Torque Specifications Description Nm lb in Throttle body nuts and bolts 9 80 Fuel injection supply manifold bolts 10 89 42 pin engine bulkhead electrical connector bolt 6 53 ...

Page 1918: ...uipped the speed control actuator cable 9A825 to the throttle lever is not adjustable cannot be cleaned The fuel injector 9F593 is electrically operated by the powertrain control module PCM 12A650 has an internal solenoid that opens a needle valve to inject fuel into the lower intake manifold atomizes the fuel as the fuel is delivered is deposit resistant Do not clean The fuel pressure relief valv...

Page 1919: ......

Page 1920: ...DIAGNOSIS AND TESTING Fuel Charging And Controls Refer to the Powertrain Control Emissions Diagnosis PC ED manual SECTION 303 04A Fuel Charging and Controls 3 8L 2003 Mustang Workshop Manual ...

Page 1921: ...GENERAL PROCEDURES Idle Speed Adjustment Powertrain Control Emissions Diagnosis PC ED manual SECTION 303 04A Fuel Charging and Controls 3 8L 2003 Mustang Workshop Manual ...

Page 1922: ...e body bore and plate area have a special coating and cannot be cleaned 1 Remove the air cleaner outlet tube 9B659 For additional information refer to Section 303 12 2 Disconnect the throttle position TP sensor electrical connector 3 Disconnect the accelerator cable 9A758 and if equipped the speed control actuator cable 9A825 4 NOTE Discard the throttle body gasket after removing the throttle body...

Page 1923: ...5 To install reverse the removal procedure ...

Page 1924: ... relieved Failure to follow these instructions may result in personal injury 1 Remove the supply manifold For additional information refer to Supply Manifold in this section 2 Remove the six fuel injectors from the supply manifold 3 CAUTION The retaining clip must be in the upper groove on the injector or the injector may become loose NOTE Inspect the two O rings from each fuel injector Install ne...

Page 1925: ......

Page 1926: ...njury 1 Disconnect the battery ground cable For additional information refer to Section 414 01 2 Remove the upper intake manifold For additional information refer to Section 303 01A 3 Disconnect the following electrical connectors 42 pin engine bulkhead connector 16 pin connector 8 pin connector A C pressure switch 4 Separate the wiring harness from the dash panel 5 Disconnect the intake manifold ...

Page 1927: ...and the 16 pin electrical connector 7 Disconnect the crankshaft position CKP sensor electrical connector 8 Disconnect the camshaft position CMP sensor electrical connector 9 NOTE Right side shown left side similar Disconnect the six fuel injector electrical connectors ...

Page 1928: ...r electrical connector on the back of the left cylinder head 11 Disconnect the engine oil pressure sender electrical connector 12 Disconnect the fuel pressure sensor electrical connector 13 Disconnect the LH heated oxygen sensor HO2S electrical connector ...

Page 1929: ...connect the 16 pin electrical connector on the back of the left cylinder head 15 Remove the wiring harness Separate the wiring harness from the fuel supply manifold 16 To install reverse the removal procedure ...

Page 1930: ...l system components the fuel system pressure must be relieved Failure to follow these instructions may result in personal injury 1 Disconnect the battery ground cable 2 Remove the upper intake manifold For additional information refer to Section 303 01A 3 Relieve the fuel pressure For additional information refer to Section 310 00 4 Disconnect the fuel line For additional information refer to Sect...

Page 1931: ...nifold bolts and remove the fuel supply manifold with the injectors 9 NOTE When the battery 10655 is disconnect and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km 10 mi or more to relearn the strategy To install reverse the removal procedure ...

Page 1932: ......

Page 1933: ...cants and Chemicals Super Premium SAE 10W 30 XO 10W30 DSP WSS M2C153 G Torque Specifications Description Nm lb ft lb in Throttle body bolts 10 89 Fuel injection supply manifold bolts 10 89 Fuel charging wiring 42 pin connector bolt 6 53 Battery supply wire nut 8 71 EGR pressure transducer bracket bolts 25 18 Generator battery supply nut 8 71 ...

Page 1934: ...tor cable 9A825 if equipped to the throttle lever is not adjustable cannot be cleaned The fuel injector 9F593 is electrically operated by the powertrain control module PCM 12A650 has an internal solenoid that opens a needle valve to inject fuel into the lower intake manifold atomizes the fuel as the fuel is delivered is deposit resistant Do not clean The fuel pressure relief valve 9H321 is used to...

Page 1935: ...nsor HO2S electrical connector 4 Ground wire electrical connector 5 LH ignition coil electrical connectors 6 Fuel pressure sensor electrical connector 7 Fuel temperature sensor electrical connector 8 Power distribution box battery feed electrical wire 9 2 pin electrical connector 10 4 pin electrical connector 11 Camshaft position sensor CMP electrical connector ...

Page 1936: ...nectors 18 Ignition coil electrical connectors 19 Throttle position TP sensor electrical connector 20 Idle air control IAC solenoid electrical connector 21 Voltage regulator electrical connector 22 Engine coolant temperature ECT electrical connector 23 Generator battery electrical connector 24 Radio ignition interference capacitor electrical connector 25 Crankshaft position CKP sensor electrical c...

Page 1937: ...DIAGNOSIS AND TESTING Fuel Charging And Controls Refer to the Powertrain Control Emissions Diagnosis PC ED manual SECTION 303 04B Fuel Charging and Controls 4 6L 2V 2003 Mustang Workshop Manual ...

Page 1938: ...GENERAL PROCEDURES Idle Speed Adjustment Powertrain Control Emissions Diagnosis PC ED manual SECTION 303 04B Fuel Charging and Controls 4 6L 2V 2003 Mustang Workshop Manual ...

Page 1939: ... area have a special coating and cannot be cleaned 1 Remove the air cleaner outlet tube 9B659 For additional information refer to Section 303 12 2 Disconnect the throttle position TP sensor electrical connector 3 Disconnect the accelerator controls Disconnect the accelerator cable 9E926 Disconnect the speed control cable 9A825 Disconnect the return spring 4 NOTE Discard the throttle body gasket Re...

Page 1940: ...Installation 1 To install reverse the removal procedure ...

Page 1941: ...ust be relieved Failure to follow these instructions may result in personal injury 1 Relieve the fuel pressure For additional information refer to Section 310 00 2 Remove the supply manifold For additional information refer to Fuel Injection Supply Manifold in this section 3 Remove the fuel injectors from the supply manifold Installation 1 NOTE Lubricate the new O rings with Super Premium SAE 10W ...

Page 1942: ...3 Install the fuel supply manifold ...

Page 1943: ...ns may result in personal injury 1 Disconnect the battery ground cable 14301 For additional information refer to Section 414 01 2 Disconnect the air cleaner outlet tube For additional information refer to Section 303 12 3 Disconnect the 42 pin connector 4 Separate the wiring harness retainers from the dash panel 5 Disconnect the following connectors Throttle position TP sensor Idle air control IAC...

Page 1944: ...r ignition coils Four fuel injectors Positive crankcase ventilation PCV hose from valve cover 7 Disconnect the following connectors RH radio ignition interference capacitor Engine coolant temperature ECT sensor 8 Disconnect the 16 pin connector ...

Page 1945: ...02 10 Disconnect the crankshaft position CKP sensor electrical connector 11 Disconnect the A C compressor clutch electrical connector 12 Disconnect the RH heated oxygen sensor HO2S electrical connector 13 Disconnect the LH heated oxygen sensor HO2S electrical connector ...

Page 1946: ...nnect the coolant reservoir electrical connector 16 Disconnect the following connectors Camshaft position CMP sensor LH radio ignition interference capacitor 17 Separate the wiring harness from the power steering reservoir bracket ...

Page 1947: ...wer supply wire Voltage regulator 19 Disconnect the following connectors LH fuel injectors LH ignition coils 20 Disconnect the following connectors Exhaust vacuum regulator EVR Ground wire 21 Disconnect the EGR pressure transducer electrical connector ...

Page 1948: ...nnector and the vacuum hose 23 Slide cover up and remove the nut and the power distribution box battery supply wire 24 NOTE These two connectors are located under the power distribution box Disconnect the two connectors 25 Disconnect the main vacuum hose ...

Page 1949: ...and the speed control cable if equipped from the bracket and position aside 28 Separate the fuel charging wiring 9D930 from the rear of the intake manifold 9424 and remove from the vehicle Installation 1 Position the fuel charging wiring in the vehicle and attach to the rear of the intake manifold ...

Page 1950: ... are fully engaged into the bracket Reposition the accelerator cable and the speed control cable if equipped and install the cables into the bracket 3 Connect the vacuum lines 4 Connect the main vacuum hose 5 Connect the two connectors ...

Page 1951: ...wire tighten the nut and close the cover 7 Connect the fuel pressure sensor and the vacuum hose 8 Connect the EGR pressure transducer electrical connector 9 Connect the following connectors Ground wire Exhaust vacuum regulator EVR ...

Page 1952: ...e following generator connectors Voltage regulator Battery supply 12 Install the wiring harness retainers to the power steering reservoir bracket 13 Connect the following connectors LH radio ignition interference capacitor CMP sensor 14 Connect the coolant reservoir electrical connector ...

Page 1953: ... Raise the vehicle 16 Connect the LH HO2S electrical connector 17 Connect the RH HO2S electrical connector 18 Connect the A C compressor clutch electrical connector 19 Connect the CKP electrical connector ...

Page 1954: ... vehicle 21 Connect the 16 pin connector 22 Connect the following connectors ECT sensor RH radio ignition interference capacitor 23 Connect the following connectors PCV hose Four fuel injectors Four ignition coils ...

Page 1955: ...t the following connectors IAC valve TP sensor 25 Install the wiring harness retainers to the dash panel 26 Connect the 42 pin connector 27 Connect the air cleaner outlet tube 28 Connect the battery ground cable ...

Page 1956: ......

Page 1957: ...e relieved Failure to follow these instructions may result in personal injury 1 Disconnect the battery ground cable 14301 For additional information refer to Section 414 01 2 Disconnect the air cleaner outlet tube For additional information refer to Section 303 12 3 Relieve the fuel pressure For additional information refer to Section 310 00 4 Disconnect the fuel line For additional information re...

Page 1958: ...IAC electrical connector and the main chassis vacuum hose 10 Remove the hose 11 Squeeze the two locking tabs and remove the accelerator cable and the speed control cable if equipped and position aside 12 Disconnect the fuel pressure sensor electrical connector and the vacuum hose ...

Page 1959: ...he ground wire 14 Disconnect the LH fuel injector electrical connectors 15 Remove the exhaust vacuum regulator EVR solenoid vacuum lines 16 Remove the bolts from the EGR pressure transducer bracket and position aside ...

Page 1960: ...st valve recirculation EGR vacuum line 19 NOTE The LH side is shown the RH is similar Remove the four bolts and remove the supply manifold with the fuel injectors attached Installation 1 NOTE The LH side is shown and the RH is similar Install the supply manifold and tighten the four bolts 2 Connect the EGR vacuum line ...

Page 1961: ...ditional information refer to Section 303 08 4 NOTE The engine is removed for clarity Position the EVR bracket and tighten the bolts 5 Connect the EVR solenoid vacuum lines 6 Connect the LH fuel injector electrical connectors 7 Connect the ground wire ...

Page 1962: ...OTE Make sure the locking clips are fully engaged into the bracket Reposition the accelerator cable and the speed control cable if equipped and install the cables into the bracket 10 Connect the hose 11 Connect the IAC electrical connector and install the main chassis vacuum hose ...

Page 1963: ...12 Connect the four RH fuel injector electrical connectors 13 Connect the PCV hose 14 Position the IAC hose and connect the hose 15 Install the throttle body 16 Connect the fuel line ...

Page 1964: ...17 Connect the air cleaner outlet tube 18 Connect the battery ground cable ...

Page 1965: ... Premium Synthetic Blend Motor Oil XO 5W20 QSP WSS M2C153 H Torque Specifications Description Nm lb in Battery ground bolt 10 89 Throttle body bolts 9 80 Fuel injection supply manifold bolts 10 89 42 pin engine bulkhead electrical connector bolt 6 53 Ignition coil cover bolts 10 89 Battery supply wire nut to power distribution box 8 71 Battery supply wire nut to generator 8 71 ...

Page 1966: ...the speed control actuator cable to the throttle lever is not adjustable cannot be cleaned The fuel injector is electrically operated by the powertrain control module PCM has an internal solenoid that opens a needle valve to inject fuel into the lower intake manifold atomizes the fuel as the fuel is delivered is deposit resistant Do not clean The fuel pressure relief valve is used to inspect and r...

Page 1967: ......

Page 1968: ...DIAGNOSIS AND TESTING Fuel Charging and Controls Refer to the Powertrain Control Emissions Diagnosis PC ED manual SECTION 303 04C Fuel Charging and Controls Cobra 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1969: ... area have a special coating and cannot be cleaned 1 Remove the air cleaner outlet tube For additional information refer to Section 303 12 2 Disconnect the throttle position TP sensor and the idle air control IAC valve electrical connectors 3 Disconnect the accelerator controls Disconnect the accelerator cable If equipped disconnect the speed control cable 4 NOTE Discard the throttle body gasket a...

Page 1970: ...5 NOTE Install a new throttle body gasket To install reverse the removal procedure ...

Page 1971: ...e instructions can result in personal injury 1 Disconnect the battery ground cable 2 Remove the exhaust gas recirculation EGR valve and the exhaust manifold to EGR valve tube For additional information refer to Section 303 08 3 Remove the bolts and the LH ignition coil cover 4 Disconnect the LH ignition coil electrical connectors 5 Disconnect the barometric pressure BARO sensor electrical connecto...

Page 1972: ...lve 7 Disconnect and remove the PCV hose 8 Disconnect the camshaft position CMP sensor electrical connector 9 Disconnect the engine coolant temperature ECT sensor electrical connector and unclip the harness from the stud ...

Page 1973: ...bolt 11 Disconnect the following The 42 pin engine bulkhead electrical connector The 16 pin electrical connector 12 Separate the wiring harness from the dash panel 13 Remove the air cleaner outlet pipe For additional information refer to Section 303 12 ...

Page 1974: ... valve electrical connectors 15 Disconnect the accelerator cable and if equipped the speed control cable 16 Remove the nuts and the throttle body spacer assembly 17 Remove the bolts and the RH ignition coil cover 18 Disconnect the RH ignition coil electrical connectors ...

Page 1975: ...e and support the vehicle For additional information refer to Section 100 02 21 Disconnect the RH heated oxygen sensor HO2S electrical connector 22 Disconnect the crankshaft position CKP sensor electrical connector 23 Disconnect the air conditioning compressor electrical connector ...

Page 1976: ...ip the harness from the bracket 25 Lower the vehicle 26 NOTE LH side shown RH side similar Disconnect the two radio ignition interference capacitor electrical connectors 27 Disconnect the eight fuel injectors ...

Page 1977: ...28 Separate the harness from the fuel supply manifold studs in four places and remove the fuel charging wiring harness from the vehicle 29 To install reverse the removal procedure ...

Page 1978: ...lure to follow these instructions can result in personal injury 1 Disconnect the battery ground cable 2 Remove the air cleaner outlet tube For additional information refer to Section 303 12 3 Release the fuel pressure For additional information refer to Section 310 00 4 Disconnect the fuel supply hose spring lock coupling For additional information refer to Section 310 00 5 Remove the exhaust gas ...

Page 1979: ...r and the vacuum hose 9 NOTE RH shown LH similar Disconnect the eight fuel injector electrical connectors 10 Separate the fuel charging wiring harness from the fuel injection supply manifold in four places 11 Remove the fuel supply manifold mounting studs ...

Page 1980: ...ve the anti rotation clips and the fuel injectors from the fuel supply manifold 14 NOTE Always install new O rings NOTE Lubricate the O rings with clean engine oil to aid installation NOTE Make sure the anti rotation clips are installed To install reverse the removal procedure ...

Page 1981: ......

Page 1982: ...hrottle body bolts 9 80 Fuel injection supply manifold bolts 10 89 42 pin engine bulkhead electrical connector bolt 6 53 Ignition coil cover bolts 10 89 Battery supply wire nut to power distribution box 8 71 Battery supply wire nut to generator 8 71 Air intake scoop bolts 25 18 Air intake scoop bracket bolt 25 18 Air intake scoop bracket nuts 25 18 Air intake scoop bracket throttle body nut 9 80 E...

Page 1983: ......

Page 1984: ...ontrol actuator cable to the throttle lever is not adjustable cannot be cleaned The fuel injector is electrically operated by the powertrain control module PCM has an internal solenoid that opens a needle valve to inject fuel into the lower intake manifold atomizes the fuel as the fuel is delivered is deposit resistant Do not clean The fuel pressure relief valve is used to inspect and relieve fuel...

Page 1985: ...e electrical connector 8 Radio ignition interference capacitor electrical connector 9 Ignition coil electrical connectors 10 Generator battery electrical connector 11 Generator field electrical connector 12 Engine coolant temperature ECT sensor electrical connector 13 Fuel pressure sensor electrical connector 14 Exhaust vacuum regulator EVR electrical connector 15 Idle air control IAC electrical c...

Page 1986: ...ctor 20 16 pin electrical connector 21 Fuel injector electrical connectors 22 Throttle position TP sensor electrical connector 23 Ignition coil electrical connectors 24 Radio ignition interference capacitor electrical connector ...

Page 1987: ...DIAGNOSIS AND TESTING Fuel Charging and Controls Refer to the Powertrain Control Emissions Diagnosis PC ED manual SECTION 303 04D Fuel Charging and Controls Mach I 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1988: ...GENERAL PROCEDURES Idle Speed Adjustment Powertrain Control Emissions Diagnosis PC ED manual SECTION 303 04D Fuel Charging and Controls Mach I 4 6L 4V 2003 Mustang Workshop Manual ...

Page 1989: ...ed 1 Remove the air intake scoop bracket For additional information refer to Section 303 12 2 Remove the air cleaner outlet tube For additional information refer to Section 303 12 3 Disconnect the throttle position TP sensor electrical connector 4 Disconnect the accelerator controls Disconnect the accelerator cable Disconnect the speed control cable Disconnect the return spring 5 NOTE Discard the ...

Page 1990: ...Installation 1 NOTE Install a new throttle body gasket To install reverse the removal procedure ...

Page 1991: ...stem components the fuel system pressure must be relieved Failure to follow these instructions can result in personal injury 1 Remove the supply manifold For additional information refer to Supply Manifold in this section 2 Remove the eight fuel injectors from the supply manifold Installation CAUTION The retaining clip must be in the upper groove on the injector or the injector can become loose 1 ...

Page 1992: ......

Page 1993: ...or additional information refer to Section 100 02 2 Disconnect the battery ground cable For additional information refer to Section 414 01 3 Remove the upper intake manifold For additional information refer to Section 303 01D 4 Disconnect the following connectors The 42 pin engine bulkhead electrical connector The 16 pin electrical connector 5 Separate the wiring harness from the dash panel 6 Remo...

Page 1994: ...ectrical connectors 8 Disconnect the heated positive crankcase ventilation PCV valve electrical connector 9 Remove the LH ignition coil cover Remove the bolts Remove the coil cover 10 Disconnect the LH ignition coil electrical connectors ...

Page 1995: ...ssion main control harness electrical connector 12 Disconnect the engine control jumper harness electrical connector 13 Remove the wiring harness bracket bolt 14 Disconnect the RH heated oxygen sensor HO2S electrical connector ...

Page 1996: ... the two radio ignition interference capacitor electrical connectors 16 Disconnect the battery supply wire from the power distribution box stud 17 NOTE The electrical connector is located under the power distribution box Disconnect the electrical connector ...

Page 1997: ...isconnect the following generator electrical connectors Battery power supply wire Voltage regulator 20 Disconnect the camshaft position CMP sensor electrical connector 21 Disconnect the engine coolant temperature ECT sensor electrical connector ...

Page 1998: ...s from the power steering reservoir bracket Installation 1 Position the wiring harness Install the wiring harness retainer onto the LH valve cover stud bolt Install the wiring harness retainer into the power steering reservoir 2 Connect the ECT sensor electrical connector 3 Connect the CMP sensor electrical connector ...

Page 1999: ...owing generator electrical connectors Battery power supply wire Voltage regulator 5 Connect the electrical connector 6 Connect the electrical connector 7 Install the battery supply wire to the power distribution box stud ...

Page 2000: ... similar Connect the two radio ignition interference capacitor electrical connectors 9 Connect the RH HO2S electrical connector 10 Install the wiring harness bracket bolt 11 Connect the engine control jumper harness electrical connector ...

Page 2001: ... main control harness electrical connector 13 Connect the LH ignition coil electrical connectors 14 Install the LH ignition coil cover and bolts 15 Connect the heated positive crankcase ventilation PCV vlave electrical connector ...

Page 2002: ...ical connectors 17 Install the RH ignition coil cover and bolts 18 Install the wiring harness retainers into the dash panel 19 Connect the following connectors The 42 pin engine bulkhead electrical connector The 16 pin electrical connector ...

Page 2003: ...When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km 10 mi or more to relearn the strategy Connect the battery ground cable For additional information refer to Section 414 01 ...

Page 2004: ...o follow these instructions can result in personal injury 1 Disconnect the battery ground cable For additional information refer to Section 414 01 2 Remove the upper intake manifold For additional information refer to Section 303 01D 3 Relieve the fuel pressure For additional information refer to Section 310 00 4 Disconnect the fuel line For additional information refer to Section 310 00 5 Positio...

Page 2005: ...d stud bolt 8 Remove the fuel supply manifold Remove the four bolts Installation 1 NOTE When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km 10 mi or more to relearn the strategy To install reverse the removal procedure ...

Page 2006: ......

Page 2007: ...lley bolt 25 18 Drive belt tensioner bolt 3 8L 82 60 Drive belt tensioner bolt 4 6L 10 89 Drive belt tensioner bolt Supercharged engine 25 18 Cooling hose mounting bolt 25 18 Belt idler support assembly bracket bolts 25 18 Air intake scoop bolts 25 18 Air intake scoop bracket bolt 25 18 Air intake scoop bracket nuts 25 18 Air intake scoop bracket throttle body nut 9 80 Exhaust gas recirculation EG...

Page 2008: ...ive belt 3 8509 Coolant pump pulley 4 8678 Belt idler pulley 5 10344 Generator pulley 6 10344 Power steering pump pulley 7 63126 Crankshaft vibration damper 8 6B209 Drive belt tensioner 9 Drive belt tensioner part of 6B209 Item Part Number Description 1 10344 Generator pulley 2 8620 Drive belt 3 8A528 Coolant pump pulley 4 3D673 Power steering pump pulley 5 6316 Crankshaft vibration damper 6 19D78...

Page 2009: ...7 6B209 Drive belt tensioner 8 19A216 Belt idler pulley 9 19A216 Belt idler pulley ...

Page 2010: ...cation Accessory Drive SECTION 303 05 Accessory Drive 2003 Mustang Workshop Manual Item Part Number Description 1 Supercharger pulley 2 8678 Belt idler pulley 3 10344 Generator pulley 4 8678 Belt idler pulley 5 6C254 Crankshaft extension pulley 6 6B209 Belt tensioner 7 8678 Belt idler pulley 8 8620 Drive belt ...

Page 2011: ...n 1 8678 Belt idler pulley 2 8678 Belt idler pulley 3 8678 Belt idler pulley 4 3A733 Power steering pulley 5 10344 Coolant pump pulley 6 6C254 Crankshaft pulley 7 6B209 Belt tensioner 8 19D784 A C clutch pulley 9 8620 Drive belt ...

Page 2012: ......

Page 2013: ...r 3 Check the drive belt for correct routing Drive Belt Cracking Chunking Wear V Ribbed Serpentine Drive Belt With Cracks Across Ribs The accessory drive has a single serpentine drive belt has an automatic drive belt tensioner does not require adjustment V Ribbed Belt With Chunks of Rib Missing Symptom Chart SECTION 303 05 Accessory Drive 2003 Mustang Workshop Manual ...

Page 2014: ...et on the drive belt during service clean the drive belt with soap and water and thoroughly rinse with clean water NOTE The drive belt tensioner arm should rotate freely without binding if the drive belt is too long A drive belt that is too long will allow the drive belt tensioner arm to go all the way to the arm travel stop under certain load conditions which will release tension to the drive bel...

Page 2015: ...edge of the pulleys noise and premature wear may occur Make sure the B drive belt rides correctly on the pulley If a drive belt tracking condition exists proceed with the following Visually check the drive belt tensioner for damage especially the mounting pad surface If the drive belt tensioner is not installed correctly the mounting surface pad will be out of position This will result in chirp an...

Page 2016: ......

Page 2017: ...the drive belt tensioner counterclockwise and remove the drive belt 2 NOTE Make sure the drive belt is correctly installed on each pulley To install reverse the removal procedure Refer to Accessory Drive for drive belt routing SECTION 303 05 Accessory Drive 2003 Mustang Workshop Manual ...

Page 2018: ...additional information refer to Section 303 12 Cobra 2 Remove the supercharger drive belt cover 3 Rotate the supercharger belt tensioner clockwise and remove the supercharger belt 4 Remove the coolant hose mounting bolt 5 Remove the belt idler support bracket assembly SECTION 303 05 Accessory Drive 2003 Mustang Workshop Manual ...

Page 2019: ... 01C All engines 7 Rotate the belt tensioner and remove the accessory drive belt 8 NOTE Make sure the accessory drive belt is correctly installed on each pulley To install reverse the removal procedure Refer to Accessory Drive and Accessory Drive Cobra for accessory drive belt routing ...

Page 2020: ...al and Installation 1 Remove the supercharger drive belt cover 2 Rotate the supercharger belt tensioner clockwise and remove the supercharger belt 3 To install reverse the removal procedure SECTION 303 05 Accessory Drive 2003 Mustang Workshop Manual ...

Page 2021: ......

Page 2022: ...al and Installation 1 Remove the drive belt For additional information refer to Accessory Drive Belt 3 8L in this section 2 Remove the belt tensioner Remove the bolt 3 To install reverse the removal procedure SECTION 303 05 Accessory Drive 2003 Mustang Workshop Manual ...

Page 2023: ...tional information refer to Section 303 12 Cobra 2 Remove the supercharger drive belt cover 3 Rotate the supercharger belt tensioner clockwise and remove the supercharger belt 4 Remove the cooling hose and tube assembly mounting bolt 5 Remove the belt idler support bracket assembly SECTION 303 05 Accessory Drive 2003 Mustang Workshop Manual ...

Page 2024: ...e belt tensioner All engines 8 Remove the accessory drive belt For additional information refer to Accessory Drive Belt Tensioner 4 6L 2V and 4V in this section 9 Remove the belt tensioner Remove the bolt and the tensioner 10 To install reverse the removal procedure Refer to Accessory Drive and Accessory Drive Cobra for accessory drive belt routing ...

Page 2025: ......

Page 2026: ...Remove the supercharger drive belt cover 2 Rotate the supercharger belt tensioner clockwise and remove the supercharger belt 3 Remove the bolts and the supercharger belt tensioner 4 To install reverse the removal procedure SECTION 303 05 Accessory Drive 2003 Mustang Workshop Manual ...

Page 2027: ......

Page 2028: ...al and Installation 1 Remove the drive belt For additional information refer to Accessory Drive Belt 3 8L in this section 2 Remove the belt idler pulley Remove the bolt 3 To install reverse the removal procedure SECTION 303 05 Accessory Drive 2003 Mustang Workshop Manual ...

Page 2029: ...op For additional information refer to Section 303 12 Cobra 2 Remove the supercharger drive belt cover 3 Rotate the supercharger belt tensioner clockwise and remove the supercharger belt 4 Remove the coolant hose mounting bolt 5 Remove the belt idler support bracket assembly SECTION 303 05 Accessory Drive 2003 Mustang Workshop Manual ...

Page 2030: ...OTE The procedure listed below can be carried out on any of the 4 6L engine accessory drive belt idler pulleys Remove the bolt and the belt idler pulley 8 To install reverse the removal procedure Refer to Accessory Drive or Accessory Drive Cobra in this section for accessory belt routing ...

Page 2031: ......

Page 2032: ...Remove the supercharger drive belt cover 2 Rotate the supercharger belt tensioner clockwise and remove the supercharger belt 3 Remove the bolt and the supercharger belt idler pulley 4 To install reverse the removal procedure SECTION 303 05 Accessory Drive 2003 Mustang Workshop Manual ...

Page 2033: ......

Page 2034: ...eres 60 80 amps Starter motor normal load current draw 130 amps Starter motor maximum load current draw amperes 400 amps Maximum starting circuit voltage drop engine at normal engine temperature 0 5 volt Torque Specifications Description Nm lb ft lb in Starter motor bolts 25 18 Starter motor ground cable nut 25 18 Starter motor solenoid S terminal nut 6 53 Starter motor solenoid B terminal nut 12 ...

Page 2035: ...y The starter interrupt relay consists of pull in coil and contacts When the ignition switch is in the START position the pull in coil is activated and pulls the contacts together current passes through the starter relay from the engine compartment power distribution box to the starter solenoid Clutch Pedal Position CPP Switch The CPP switch for a manual transmission closes when the clutch pedal i...

Page 2036: ......

Page 2037: ... result in personal injury WARNING When using a remote starter switch or jumper wire be sure the ignition switch is in the OFF position and the transmission is in PARK A T or Neutral M T with the parking brake control fully applied 1 Verify the customers concern by operating the starting system to duplicate the conditions 2 Inspect to determine if any of the following mechanical or electrical conc...

Page 2038: ...Go To Pinpoint Test B The engine cranks slowly Battery Starter motor solenoid Circuit Go To Pinpoint Test C Unusual starter noise Starter motor mounting Starter motor Incorrect starter drive engagement Go To Pinpoint Test D The starter spins but the engine does not crank Starter Motor INSPECT the starter motor mounting and engagement REPAIR as necessary Damaged flywheel ring gear teeth INSPECT the...

Page 2039: ...umper wire to the positive terminal of the battery and touch the other end to the starter solenoid S terminal Does the starter solenoid engage Yes GO to A4 No INSTALL a new starter motor REFER to Starter Motor 3 8L or Starter Motor 4 6L TEST the system for normal operation A4 TEST THE STARTER MOTOR RELAY Carry out the relay component test on the starter motor relay Refer to the relay component tes...

Page 2040: ...atic transmissions GO to B2 For manual transmissions GO to B5 B2 CHECK CIRCUIT 32 RD LB FOR VOLTAGE AT THE DIGITAL TR SENSOR Key in OFF position Disconnect Digital TR Sensor C110 Key in START position Measure the voltage between the digital TR sensor C110 pin 10 circuit 32 RD LB and ground while holding the key in the START position Is the voltage greater than 10 volts Yes GO to B3 No GO to B7 B3 ...

Page 2041: ...5 Key in START position Measure the voltage between the clutch pedal switch C255 pin 2 circuit 32 RD LB and ground while holding the key in the START position Is the voltage greater than 10 volts Yes GO to B6 No GO to B7 B6 CHECK CIRCUIT 33 WH PK 32 RD LB FOR OPEN Key in OFF position Measure the resistance between the clutch pedal switch C255 pin 1 circuit 33 WH PK 32 RD LB and the starter motor r...

Page 2042: ...voltage greater than 10 volts Yes GO to B9 No REPAIR circuit 1050 LG VT TEST the system for normal operation B9 CHECK THE IGNITION SWITCH Carry out the ignition switch component test Refer to Refer to Wiring Diagrams Cell 149 for schematic and connector information Does the ignition switch test good Yes REPAIR circuit 33 WH PK TEST the system for normal operation No INSTALL a new ignition switch T...

Page 2043: ... ground Is the voltage 12 5 volts or greater Yes GO to C2 No REPAIR the circuit between the battery and the starter solenoid CLEAN and TIGHTEN the connections at the battery terminals TEST the system for normal operation C2 CHECK MOTOR GROUND CIRCUIT Carry out the Motor Ground Circuit test refer to Component Tests in this section Is the ground OK Yes INSTALL a new starter motor REFER to Starter Mo...

Page 2044: ...g connector and the component Starter Motor Motor Feed Circuit 1 Make sure the battery is fully charged Perform a battery load test For additional information refer to Section 414 00 2 Disconnect the inertia fuel shut off IFS switch 3 Connect a remote starter switch between the starter solenoid S terminal and the battery positive terminal 4 Connect the Digital Multimeter positive lead to the batte...

Page 2045: ...al is less than 0 5 volts the concern is either in the connections at the starter solenoid or in the solenoid contacts Go to Step 8 If the voltage reading is greater than 0 5 volts at the B terminal the concern is either the positive battery cable or connections Go to Step 9 8 Remove the cables from solenoid B S and M terminals Clean the cables and connections and reinstall the cables to the corre...

Page 2046: ...nnect the Digital Multimeter positive lead to the starter motor housing the connection must be clean and free of rust or grease Connect the negative lead to the negative battery terminal 2 Engage the remote starter switch Read and record the voltage The voltage reading should be less than 0 3 volts 3 If the voltage is greater than 0 3 volts clean the negative cable connections at the battery body ...

Page 2047: ......

Page 2048: ... motor For additional information refer to Starter Motor 3 8L or Starter Motor 4 6L in this section 3 If the starter drive gear and the flywheel ring gear are not fully meshing and both of the gears are scored or damaged install a new starter motor For additional information refer to Starter Motor 3 8L or Starter Motor 4 6L in this section If necessary install a new flywheel For additional informa...

Page 2049: ......

Page 2050: ...able For additional information refer to Section 414 01 2 Remove the power distribution box cover 3 Remove the starter relay from the power distribution box Installation 1 To install reverse the removal procedure SECTION 303 06 Starting System 2003 Mustang Workshop Manual ...

Page 2051: ......

Page 2052: ...ilure to follow these instructions may result in personal injury WARNING When working in area of the starter motor be careful to avoid touching hot exhaust components Failure to follow these instructions may result in personal injury NOTE When working on the starter system make sure the anti theft system is deactivated if equipped 1 Disconnect the battery ground cable For additional information re...

Page 2053: ...6 Remove the bolts and the starter motor Installation 1 To install reverse the removal procedure ...

Page 2054: ... injury WARNING When working in area of the starter motor be careful to avoid touching hot exhaust components Failure to follow these instructions can result in personal injury NOTE When working on the starter system make sure the anti theft system is deactivated if equipped 1 Disconnect the battery ground cable For additional information refer to Section 414 01 2 Raise and support the vehicle For...

Page 2055: ...l the two lower bolts finger tight then install the upper concealed bolt Tighten all three bolts to specification Install the three starter motor bolts 3 Connect the starter motor solenoid and starter motor cable connections 4 Install the red starter solenoid safety cap 5 Lower the vehicle 6 Connect the battery ground cable ...

Page 2056: ......

Page 2057: ...ring order 1 4 2 5 3 6 Spark plug gap mm in 1 32 1 42 0 052 0 056 Spark plug type production LH AWSF 42E Spark plug type production RH AWSF 42EG Spark plug type service AWSF 42EE Silicone Brake Caliper Grease and Dielectric Compound D7AZ 19A331 A ESE M1C171 A Torque Specifications Description Nm lb ft lb in Spark plugs 15 11 Ignition coil bolts 7 52 ...

Page 2058: ...electrode to ground The spark plug 12405 changes the high voltage pulse into a spark which ignites the fuel and air mixture originally equipped on the vehicle has a platinum enhanced active electrode for long life The crankshaft position CKP sensor 6C315 NOTE Initial engine ignition timing is set at 10 degrees 2 degrees before top dead center BTDC and is not adjustable is a variable reluctance sen...

Page 2059: ......

Page 2060: ...DIAGNOSIS AND TESTING Engine Ignition Refer to the Powertrain Control Emissions Diagnosis PC ED manual SECTION 303 07A Engine Ignition 3 8L 2003 Mustang Workshop Manual ...

Page 2061: ...6 must be connected to the correct ignition coil terminal Mark spark plug wire locations before removing them Twist while pulling upward to disconnect the spark plug wires 4 Disconnect the accelerator cable retaining clamp from the ignition coil stud bolt SECTION 303 07A Engine Ignition 3 8L 2003 Mustang Workshop Manual Material Item Specification Silicone Brake Caliper Grease and Dielectric Compo...

Page 2062: ... Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug wire coil boot NOTE Be sure to reinstall the radio ignition interference capacitor 18801 under the correct mounting bolt To install reverse the removal procedure ...

Page 2063: ...rk plug wire 12286 locations before removing them 1 Using the special tool remove the spark plug wire from the spark plug using a twisting motion 2 Twist while pulling upward to disconnect the spark plug wires from the ignition coil 12029 SECTION 303 07A Engine Ignition 3 8L 2003 Mustang Workshop Manual Special Tool s Remover Spark Plug Wire 303 106 T74P 6666A Material Item Specification Silicone ...

Page 2064: ...oots so the spark plug wires do not contact the exhaust manifold NOTE Apply silicone brake caliper grease and dielectric compound to the inside of spark plug and ignition coil boots of the spark plug wire To install reverse the removal procedure ...

Page 2065: ...ve the spark plug wires from the spark plugs using a twisting motion 3 NOTE Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs NOTE If an original spark plug is reused make sure it is installed in the same cylinder from which it was taken New spark plugs can be used in any cylinder NOTE Left side shown right side similar Remove the spark plug...

Page 2066: ...sed by excessive oil entering the combustion chamber through worn rings and pistons excessive clearance between valve guides and stems or worn or loose bearings Correct the oil problem Install a new spark plug 6 Inspect for carbon fouling This can be identified by black dry fluffy carbon deposits on the insulator tips exposed shell surfaces and electrodes This may be caused by too cold a plug dirt...

Page 2067: ...deposits on the insulator indicate engine damage Install a new spark plug 9 Inspect for overheating This can be identified by a white or light gray insulator with small black or gray brown spots and a bluish burnt appearance of the electrodes This may be caused by engine overheating the wrong type of fuel loose spark plugs too hot a plug low fuel pump pressure or incorrect ignition timing Install ...

Page 2068: ...y sudden acceleration Clean the spark plug 11 CAUTION Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust manifold NOTE Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug wire boots To install reverse the removal procedure Adjust the spark plug gap as necessary ...

Page 2069: ......

Page 2070: ...eneral Specifications Item Specification Base ignition timing 10 degrees 2 degrees non adjustable Firing order 1 3 7 2 6 5 4 8 Spark plug gap mm in 1 32 1 42 0 052 0 056 Spark plug type AWSF 32PP Torque Specifications Description Nm lb ft lb in Spark plugs 15 11 Coil on plug bolts 10 89 ...

Page 2071: ...center BTDC and is not adjustable For additional information refer to the Powertrain Control Emissions Diagnosis PC ED manual is a variable reluctance sensor triggered by a 36 minus 1 tooth trigger pulse wheel located on the crankshaft 6303 inside the engine front cover 6019 The sine wave type signal generated from the crankshaft position sensor provides two types of information position of the cr...

Page 2072: ......

Page 2073: ...DIAGNOSIS AND TESTING Engine Ignition Refer to the Powertrain Control Emissions Diagnosis PC ED manual SECTION 303 07B Engine Ignition 4 6L 2V 2003 Mustang Workshop Manual ...

Page 2074: ... to Section 303 12 3 NOTE One ignition coil is shown and the others are similar Disconnect the connector from the ignition coil 12029 4 Remove the bolt and the ignition coil Installation 1 NOTE Verify the ignition coil spring is correctly located inside the ignition coil boot and there is no damage to the tip of the boot To install reverse the removal procedure SECTION 303 07B Engine Ignition 4 6L...

Page 2075: ......

Page 2076: ...nder NOTE One spark plug is shown others are similar Remove the spark plugs 3 Inspect for gap bridged This can be identified by a deposit build up closing the gap between electrodes This can be caused by oil or carbon fouling Clean the spark plug 4 Inspect for oil fouling This can be identified by wet black deposits on the insulator shell bore electrodes This can be caused by excessive oil enterin...

Page 2077: ...cold a plug dirty air cleaner damaged fuel pump too rich a fuel mixture or excessive idling Clean the spark plug 6 Inspect for normal burning This can be identified by light tan or gray deposits on the firing tip 7 Inspect for pre ignition This can be identified by melted electrodes and possibly a blistered insulator Metallic deposits on insulator indicate engine damage Install a new spark plug ...

Page 2078: ...sed by engine overheating wrong type of fuel loose spark plugs too hot a plug low fuel pump pressure or incorrect ignition timing Install a new spark plug 9 Inspect for fused spot deposits This can be identified by melted or spotty deposits resembling bubbles or blisters This may be caused by sudden acceleration Clean the spark plug Installation 1 Adjust the spark plug gap as necessary ...

Page 2079: ...2 To install reverse the removal procedure ...

Page 2080: ...al Specifications Item Specification Ignition timing 10 degrees BTDC 2 degrees non adjustable Firing order 1 3 7 2 6 5 4 8 Spark plug gap mm in 1 32 1 42 0 052 0 056 Spark plug type AWSF 32EM Torque Specifications Description Nm lb ft lb in Spark plugs 15 11 Ignition coil cover bolts 10 89 ...

Page 2081: ...P sensor NOTE Initial engine ignition timing is set at 10 degrees 2 degrees before top dead center BTDC and is not adjustable For additional information refer to the Powertrain Control Emissions Diagnosis PC ED manual is a variable reluctance sensor triggered by a 36 minus 1 tooth trigger pulse wheel located on the crankshaft inside the engine front cover The sine wave type signal generated from t...

Page 2082: ......

Page 2083: ...DIAGNOSIS AND TESTING Engine Ignition Refer to the Powertrain Control Emissions Diagnosis PC ED manual SECTION 303 07C Engine Ignition 4 6L 4V 2003 Mustang Workshop Manual ...

Page 2084: ...pe For additional information refer to Section 303 12 3 Remove the RH ignition coil cover bolts and the cover 4 Remove the ignition coils 1 Disconnect the electrical connectors 2 Remove the ignition coils SECTION 303 07C Engine Ignition 4 6L 4V 2003 Mustang Workshop Manual Material Item Specification Silicone Brake Caliper Grease and Dielectric Compound D7AZ 19A331 A or equivalent ESE M1C171 A ...

Page 2085: ...5 Remove the LH ignition coil cover bolts and the cover 6 Remove the ignition coils 1 Disconnect the connectors 2 Remove the ignition coils ...

Page 2086: ...oil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot To install reverse the removal procedure Apply a light coat of dielectric grease to the inside of the ignition coil boots ...

Page 2087: ...re removing the spark plugs NOTE If an original spark plug is used make sure it is installed in the same cylinder from which it was taken New spark plugs can be used in any cylinder Remove the RH spark plugs 3 Remove the LH spark plugs 4 Inspect the spark plugs Install new spark plugs as necessary For additional information refer to Section 303 00 5 Adjust the spark plug gap as necessary SECTION 3...

Page 2088: ...6 To install reverse the removal procedure ...

Page 2089: ...GR Bullitt 10 89 EGR valve bolts 10 89 EGR valve to exhaust manifold tube fitting 35 26 EGR tube to exhaust manifold fitting except Bullitt 40 30 EGR tube to exhaust manifold fitting 35 26 Vacuum accessory bracket fasteners 10 89 Air intake scoop bolts 25 18 Air intake scoop bracket bolt 25 18 Air intake scoop bracket nuts 25 18 Air intake scoop bracket throttle body nut 9 80 Exhuast gas recircula...

Page 2090: ...sists of the positive crankcase ventilation PCV system exhaust gas recirculation EGR system Typical Vehicle Emission Control Information VECI Decal The Vehicle Emission Control Information VECI decal shows the components of the emission control system the correct vacuum hose routing SECTION 303 08 Engine Emission Control 2003 Mustang Workshop Manual Item Part Number Description 1 Adjustment proced...

Page 2091: ...odule A metering orifice in the EGR valve to exhaust manifold tube restricts the flow rate when the EGR valve is open The PCV valve controls the amount of ventilating air and blow by gases going to the intake manifold prevents a backfire from reaching the crankcase The EGR valve to exhaust manifold tube connects the exhaust manifold to the EGR valve has two tubes connecting to the EGR transducer f...

Page 2092: ......

Page 2093: ...DIAGNOSIS AND TESTING Engine Emission Control Refer to the Powertrain Control Emissions Diagnosis PC ED manual SECTION 303 08 Engine Emission Control 2003 Mustang Workshop Manual ...

Page 2094: ... 6L 2V is shown The 3 8L is similar 1 Disconnect the vacuum hose 2 Disconnect the EGR tube from the EGR valve 3 Remove the two bolts the EGR valve and the gasket 4 NOTE Install a new gasket To install reverse the removal procedure SECTION 303 08 Engine Emission Control 2003 Mustang Workshop Manual ...

Page 2095: ......

Page 2096: ...he accelerator cable bracket bolts 3 Release the clip and position the accelerator cable bracket and the cables aside 4 Disconnect the electrical connectors from the fuel pulse damper EGR vacuum regulator solenoid supercharger bypass vacuum solenoid and the differential pressure feedback EGR system SECTION 303 08 Engine Emission Control 2003 Mustang Workshop Manual ...

Page 2097: ...ure feedback EGR system 6 Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid and the actuator 7 Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid 8 Disconnect the vacuum hose from the EGR valve ...

Page 2098: ... the back of the supercharger and position the vacuum harness aside 10 Remove the vacuum accessory bracket mounting nut 11 Remove the mounting bolts and the vacuum accessory bracket 12 Disconnect the exhaust manifold to EGR valve tube ...

Page 2099: ...13 NOTE Discard the EGR valve gasket Remove the mounting bolts and the EGR valve 14 NOTE Install a new EGR valve gasket To install reverse the removal procedure ...

Page 2100: ...um hose 3 Remove the two bolts and remove the EGR valve and gasket 3 CAUTION Do not use metal scrapers wire brushes power abrasive disks or other abrasive means to clean the sealing surfaces These tools cause scratches and gouges which make leak paths Use a plastic scraping tool to remove all traces of old sealant Clean and inspect the mating surfaces 4 To install reverse the removal procedure Ins...

Page 2101: ......

Page 2102: ...ist For additional information refer to Section 100 02 2 Disconnect the exhaust gas recirculation EGR valve tube from the exhaust manifold 3 Remove the differential feedback exhaust gas recirculation EGR system vacuum hoses and the bracket bolts Position the bracket assembly aside 4 Disconnect the EGR tube from the EGR valve SECTION 303 08 Engine Emission Control 2003 Mustang Workshop Manual ...

Page 2103: ...5 Remove the exhaust manifold to EGR valve tube 6 To install reverse the removal procedure ...

Page 2104: ...Gas Recirculation EGR Valve Cobra in this section 2 With the vehicle in NEUTRAL position it on a hoist For additional information refer to Section 100 02 3 Disconnect the exhaust manifold to EGR valve tube 4 Remove the exhaust manifold to EGR tube from the engine compartment 5 To install reverse the removal procedure SECTION 303 08 Engine Emission Control 2003 Mustang Workshop Manual ...

Page 2105: ... 303 12 2 Disconnect the exhaust gas recirculation EGR tube from the EGR valve 3 With the vehicle in NEUTRAL position it on a hoist For additional information refer to Section 100 02 4 Disconnect the EGR tube from the exhaust manifold 5 Disconnect the hoses and remove the tube from the vehicle Installation SECTION 303 08 Engine Emission Control 2003 Mustang Workshop Manual ...

Page 2106: ...1 To install reverse the removal procedure ...

Page 2107: ... 6L 4V and 3 8L are similar NOTE Bolts may be used in place of nuts on some applications Remove the differential pressure feedback EGR 1 Disconnect the connector 2 Remove the hoses 3 Remove the nuts and the differential pressure feedback EGR 2 To install reverse the removal procedure SECTION 303 08 Engine Emission Control 2003 Mustang Workshop Manual ...

Page 2108: ...ir intake scoop For additional information refer to Section 303 12 All vehicles 2 Remove the exhaust gas recirculation EGR vacuum regulator solenoid Disconnect the electrical connector Remove the bolts 3 To install reverse the removal procedure SECTION 303 08 Engine Emission Control 2003 Mustang Workshop Manual ...

Page 2109: ...rankcase Ventilation PCV Hose Removal and Installation 1 Disconnect the hose on the PCV valve 2 Twist and remove the PCV valve 3 To install reverse the removal procedure SECTION 303 08 Engine Emission Control 2003 Mustang Workshop Manual ...

Page 2110: ......

Page 2111: ...lb ft lb in Air cleaner and duct assembly bolt 7 62 Coolant supply and return manifold a Charge air cooler bolts a Supercharger mounting bolts a Air intake scoop bolts 25 18 Air intake scoop bracket bolt 25 18 Air intake scoop bracket nuts 25 18 Air intake scoop bracket throttle body nut 9 80 Exhaust gas recirculation EGR vacuum regulator solenoid bolts 10 89 ...

Page 2112: ...L air cleaner ACL element mass air flow MAF sensor air cleaner outlet tube air cleaner and duct assembly The air intake system cleans intake air with an air cleaner element measures air flow with a MAF sensor For additional information refer to Section 303 14 SECTION 303 12 Intake Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 2113: ...num Air from the supercharger is routed through the charge air cooler CAC then to the intake manifold The resulting denser air charge in the combustion chamber provides for a higher power output of the engine over a non supercharged engine of the same displacement NOTE It is not possible to increase manifold pressure or engine power output by altering the bypass valve or the actuator At partial th...

Page 2114: ......

Page 2115: ...AGNOSIS AND TESTING Intake Air Distribution and Filtering Refer to the Powertrain Control Emissions Diagnosis PC ED manual SECTION 303 12 Intake Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 2116: ...3 8L Removal and Installation 1 Remove the air cleaner outlet tube 1 Loosen the clamps 2 Disconnect the hose 3 Remove the tube 2 To install reverse the removal procedure SECTION 303 12 Intake Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 2117: ...6L 2V Removal and Installation 1 Disconnect the hoses 2 Remove the air cleaner outlet tube 1 Loosen the clamps 2 Remove the tube 3 To install reverse the removal procedure SECTION 303 12 Intake Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 2118: ......

Page 2119: ...isconnect the intake air temperature IAT sensor All vehicles 2 Disconnect the vacuum hose 3 Disconnect the breather hose NOTE Cobra shown Mach I similar 4 Loosen the clamps and remove the air cleaner outlet pipe SECTION 303 12 Intake Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 2120: ...5 To install reverse the removal procedure ...

Page 2121: ...the throttle body For additional information refer to Air Cleaner Outlet Pipe 3 8L in this section 2 Disconnect the connector 3 Remove the bolt 4 Remove the air cleaner and duct assembly 5 To install reverse the removal procedure SECTION 303 12 Intake Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 2122: ......

Page 2123: ... All vehicles 2 Remove the air cleaner outlet tube from the throttle body For additional information refer to Air Cleaner Outlet Pipe 4 6L 2V or Air Cleaner Outlet Pipe 4 6L 4V in this section 3 Remove the bolt 4 Remove the air cleaner and duct assembly SECTION 303 12 Intake Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 2124: ...5 To install reverse the removal procedure ...

Page 2125: ...ation refer to Air Cleaner Outlet Pipe 3 8L in this section 2 Disconnect the connector 3 Remove the mass air flow MAF sensor 1 Release the clips 2 Remove the MAF sensor assembly 4 Remove the air cleaner element 5 To install reverse the removal procedure SECTION 303 12 Intake Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 2126: ......

Page 2127: ...information refer to Air Cleaner Outlet Pipe 4 6L 2V in this section 2 Remove the mass air flow MAF assembly 1 Release the clip 2 Remove the MAF sensor assembly and position aside 3 Remove the air cleaner element 4 To install reverse the removal procedure SECTION 303 12 Intake Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 2128: ......

Page 2129: ...ir Cleaner Element 4 6L 4V Removal and Installation 1 Open the air cleaner housing 2 Remove the element 3 To install reverse the removal procedure SECTION 303 12 Intake Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 2130: ...sconnect the air intake scoop water drain hoses 3 Remove the air intake scoop from the air intake scoop bracket Remove the two air intake scoop bolts Lift the air intake scoop from the air intake bracket studs 4 To install reverse the removal procedure SECTION 303 12 Intake Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 2131: ......

Page 2132: ...nut at the throttle body 3 Remove the exhaust gas recirculation EGR vacuum regulator solenoid bolts and position the EGR vacuum regulator solenoid aside 4 Remove the air intake scoop bracket nuts and the air intake scoop bracket bolt and remove the air intake scoop bracket from the engine 5 To install reverse the removal procedure SECTION 303 12 Intake Air Distribution and Filtering 2003 Mustang W...

Page 2133: ......

Page 2134: ...isconnect the coolant hose 5 Remove the supercharger belt For additional information refer to Section 303 05 6 Remove the air cleaner outlet tube For additional information refer to Section 303 12 7 Disconnect the throttle position TP sensor and the idle air control IAC valve electrical connectors SECTION 303 12 Intake Air Distribution and Filtering 2003 Mustang Workshop Manual Material Item Speci...

Page 2135: ...fuel supply spring lock coupler For additional information refer to Section 310 00 10 Disconnect the accelerator controls Disconnect the accelerator cable If equipped disconnect the speed control cable 11 Remove the accelerator cable bracket bolts ...

Page 2136: ...cable bracket and the cables aside 14 Disconnect the electrical connectors from the fuel pulse damper EGR vacuum regulator solenoid supercharger bypass vacuum solenoid and the differential pressure feedback EGR system 15 Disconnect the vacuum hoses from the differential pressure feedback EGR system ...

Page 2137: ...olenoid and the actuator 17 Disconnect the vacuum hoses from the fuel pulse damper and the EGR vacuum regulator solenoid 18 Disconnect the vacuum hose from the EGR valve 19 Disconnect the vacuum hoses at the back of the supercharger and position the vacuum harness aside ...

Page 2138: ...um accessory bracket mounting nut 21 Remove the mounting bolts and the vacuum accessory bracket 22 Disconnect the exhaust manifold to EGR valve tube 23 Disconnect the barometric pressure BARO sensor electrical connector ...

Page 2139: ...Separate the fuel charging wiring harness from the fuel injection supply manifold in four places and position the harness aside 26 Remove the ten bolts the intake manifold supercharger and fuel supply manifold as an assembly 27 Disconnect and remove the PCV hoses ...

Page 2140: ...he coolant supply and return manifold 29 Remove the coolant supply and return tubes and seals 30 Remove the fuel supply manifold mounting studs 31 Remove the fuel supply manifold and fuel injectors as an assembly ...

Page 2141: ... Remove the bolts and the CAC in the sequence shown 34 Inspect the CAC plenum gasket and install a new gasket if necessary 35 To install reverse the removal procedure 36 Apply a bead of sealant in the areas shown on the supercharger flange between the CAC and the supercharger ...

Page 2142: ... to 2 Nm 18 lb in 2 Tighten to 6 Nm 53 lb in 38 Tighten the supercharger and CAC cooler assembly to lower intake manifold bolts in the sequence shown in three stages 1 Tighten to 2 Nm 18 lb in 2 Tighten to 25 Nm 18 lb ft 3 Tighten an additional 90 degrees 39 Tighten the coolant supply and return manifold in two stages 1 Tighten to 10 Nm 89 lb ft 2 Tighten an additional 90 degrees ...

Page 2143: ...ntake manifold gaskets and install new gaskets if necessary Tighten the lower intake manifold bolts in the sequence shown 41 Fill and bleed the supercharger cooling system For additional information refer to Section 303 03B ...

Page 2144: ... Workshop Manual General Specifications Item Specification MERPOL O ring Seal Lubricant ESE M99B144 B Torque Specifications Description Nm lb ft lb in Evaporative emissions canister and bracket assembly bolts 25 18 Evaporative emission canister purge valve nuts 7 62 ...

Page 2145: ...ueling vapor recovery ORVR system SECTION 303 13 Evaporative Emissions 2003 Mustang Workshop Manual Item Part Number Description 1 9F980 Evaporative emission test port 2 9C915 Evaporative emission canister purge valve 3 9F945 Canister vent solenoid 4 9D653 Evaporative emission canister 5 9C047 Fuel vapor control valve tube assembly ...

Page 2146: ...ter through a vapor line to the engine when the EVAP canister purge valve is opened by the PCM The fuel tank pressure FTP sensor monitors the pressure levels in the fuel tank communicates the pressure reading to the PCM during the OBDII leak test is located in line above the fuel tank and is serviced as part of the fuel vapor control valve tube assembly The evaporative emission canister is located...

Page 2147: ...ly requires two grommets to seal the fuel vapor control valve and fuel vapor vent valve to the fuel tank The evaporative emission EVAP system monitor is a self test strategy within the PCM which tests the integrity of the EVAP system monitors the EVAP system for leaks monitors electronic EVAP components for irrationally high or low voltages monitors for correct EVAP system operation utilizes intak...

Page 2148: ... Worldwide Diagnostic System WDS 418 F224 New Generation STAR NGS Tester 418 F052 or equivalent scan tool Item Part Number Description 1 9030 Fuel filler cap 2 9B593 Fuel vapor vent valve 3 9C052 Fuel tank pressure sensor 4 9C915 Evaporative emission canister purge valve 5 9F945 Canister vent solenoid 6 9D653 Evaporative emission canister 7 9002 Fuel tank 8 9B190 Fuel vapor control valve 9 9189 Fu...

Page 2149: ...rge valve during refueling and to prevent the collection of liquid fuel in the fuel vapor hoses by overfilling the fuel tank Fuel Vapor Vent Valve FVV Assembly The fuel vapor vent valve FVV assembly is mounted on the top of the fuel tank It is used to control the flow of fuel vapors entering the EVAP system The head portion of the assembly prevents the fuel tank from overfilling during refueling T...

Page 2150: ...one inch diameter tube blocks vapors from rushing back up the fuel filler pipe A fuel vapor control valve controls the flow of vapors out of the fuel tank The valve closes when the liquid level reaches a height associated with fuel tank usable capacity The valve accomplishes the following limits the total amount of fuel that can be dispensed into the fuel tank prevents liquid gasoline from exiting...

Page 2151: ...ry out the PCM KOEO self test 6 If the DTCs retrieved are related to the concern go to the PCM Diagnostic Trouble Code DTC Index to continue diagnostics 7 If the concern remains after the inspection determine the symptom GO to Symptom Chart PCM Diagnostics Trouble Code DTC Index Symptom Chart EVAP lines or hoses Vacuum lines or hoses DTC Description Source Action P0442 Small leak detected in EVAP ...

Page 2152: ...s at 75 fuel fill Vapor generation limit more than 0 625 kPa 2 5 inches H 2 O over 120 seconds A1 VISUALLY INSPECT THE COMPONENTS FOR SMALL LEAKS Check for the presence of a fuel filler cap Do not tighten or check for correct installation at this time Verify the canister vent solenoid is correctly seated on the EVAP canister Check for cut or loose connections to fuel vapor hoses tubes and connecti...

Page 2153: ...ARRY OUT the evaporative emissions repair verification drive cycle REFER to Evaporative Emission Repair Verification Drive Cycle in this section A5 CHECK FOR CONCERN OTHER THAN THE FUEL FILLER CAP Refer to previous test results Did the system pass the evaporative emission system leak test carried out in pinpoint test Step A2 Yes CARRY OUT the evaporative emission system leak test REFER to Evaporat...

Page 2154: ...cycle REFER to Evaporative Emission Repair Verification Drive Cycle in this section No DISCONTINUE pressurizing the system GO to A8 A8 CHECK FOR SMALL LEAK FROM THE EVAP RETURN TUBE TO THE FUEL VAPOR TEE Disconnect the EVAP canister purge outlet tube at the fuel vapor tee Plug the opening in the EVAP canister purge outlet tube Connect the Evaporative Emission System Leak Tester to the EVAP test po...

Page 2155: ... leak test REFER to Evaporative Emission System Leak Test in this section If the system passes the leak test CARRY OUT the evaporative emissions repair verification drive cycle REFER to Evaporative Emission Repair Verification Drive Cycle in this section No GO to A6 Test Step Result Action to Take NOTE Condition DTC P0455 set 1 74 kPa 7 0 inches H 2 O over 30 seconds NOTE Condition DTC P1443 set 1...

Page 2156: ...tem Leak Test in this section If the system passes the leak test CARRY OUT the evaporative emission repair verification drive cycle REFER to Evaporative Emission Repair Verification Drive Cycle in this section B4 CHECK FOR BLOCKAGE BETWEEN THE EVAP CANISTER PURGE VALVE AND FUEL VAPOR TEE Key in ON position Close the canister vent solenoid Refer to Canister Vent Solenoid Closing Procedure in this s...

Page 2157: ...ycle in this section No INSTALL a new fuel tank pressure sensor REFER to Fuel Tank Pressure Sensor in this section CARRY OUT the evaporative emission system leak test REFER to Evaporative Emission System Leak Test in this section If the system passes the leak test CARRY out the evaporative emission repair verification drive cycle REFER to Evaporative Emission Repair Verification Drive Cycle in thi...

Page 2158: ... IDLE Connect the EVAP canister outlet tube Remove the plug from the EVAP return tube and reconnect the tube to the intake manifold Verify that the fuel filler cap is correctly installed Key in ON position Access PCM PIDs FTP V and EVAPPDC Start the engine and allow to idle Monitor the FTP V and EVAPPDC PIDs When PID EVAPPDC is zero is PID FTP V reading below 2 40 volts Yes INSTALL a new EVAP cani...

Page 2159: ...ng Procedure in this section Pressurize the EVAP system to 3 48 kPa 14 inches H 2 O Is the FTP FTP V PID reading 3 11 kPa to 3 86 kPa 12 5 to 15 5 inches H 2 O 4 22 to 4 90 volts Yes GO to D4 No REFER to the Powertrain Control Emissions Diagnosis PC ED manual D4 TEST TO DETERMINE BLOCKAGE LOCATION Open the canister vent solenoid Does the pressure drop immediately Yes GO to D5 No GO to D7 D5 TEST F...

Page 2160: ...the evaporative emission repair verification drive cycle REFER to Evaporative Emission Repair Verification Drive Cycle in this section D7 TEST FOR BLOCKAGE IN FRESH AIR VENT HOSE Disconnect the fresh air vent hose from the fuel filler pipe inside the luggage compartment Pressurize the EVAP system to 3 48 kPa 14 inches H 2 O Does the pressure drop immediately Yes INSTALL a new fresh air vent hose C...

Page 2161: ...ssion Repair Verification Drive Cycle in this section No GO to D10 D10 TEST FOR BLOCKAGE IN CANISTER VENT SOLENOID HOSE Disconnect the canister vent solenoid hose from the canister vent solenoid Pressurize the EVAP system to 3 48 kPa 14 inches H 2 O Does the pressure drop immediately Yes INSTALL a new canister vent solenoid hose CARRY OUT a leak test REFER to Evaporative Emission System Leak Test ...

Page 2162: ...RY OUT the evaporative emission repair verification drive cycle REFER to Evaporative Emission Repair Verification Drive Cycle in this section No GO to D13 D13 TEST FOR BLOCKAGE IN CANISTER INLET ELBOW Disconnect the fuel vapor control valve tube assembly from the evaporative emissions canister inlet elbow Pressurize the EVAP system to 3 48 kPa 14 inches H 2 O Does the pressure drop immediately Yes...

Page 2163: ...s complete REFER to Symptom Chart E3 ISOLATE SYSTEM LEAK FROM FRONT TO REAR Disconnect EVAP canister purge outlet tube from fuel vapor control valve tube assembly and plug both ends Connect the Evaporative Emission System Leak Tester to the evaporative emissions test port Pressurize the EVAP system to 3 48 kPa 14 inches H 2 O Does the pressure drop immediately Yes GO to E4 No GO to E9 E4 TEST FUEL...

Page 2164: ...to Evaporative Emission System Leak Test on this section If the system passes the leak test CARRY OUT the evaporative emission repair verification drive cycle REFER to Evaporative Emission Repair Verification Drive Cycle in this section No RECONNECT the evaporative emissions test port tube to the EVAP canister purge outlet tube GO to E7 E7 TEST FOR EVAP CANISTER PURGE OUTLET TUBE LEAK Disconnect t...

Page 2165: ... SYSTEM Reconnect all components Connect the Evaporative Emission System Leak Tester to the fuel filler pipe Close the canister vent solenoid Refer to Canister Vent Solenoid Closing Procedure in this section Pressurize the EVAP system to 3 48 kPa 14 inches H 2 O Open the canister vent solenoid Does the pressure drop immediately Yes GO to E14 No GO to E10 E10 TEST FOR BLOCKAGE IN THE FRESH AIR VENT...

Page 2166: ...on If the system passes the leak test CARRY OUT the evaporative emission repair verification drive cycle REFER to Evaporative Emission Repair Verification Drive Cycle in this section No GO to E13 E13 TEST FOR BLOCKAGE IN CANISTER VENT SOLENOID HOSE Disconnect the canister vent solenoid hose from the canister vent solenoid Pressurize the EVAP system to 3 48 kPa 14 inches H 2 O Does the pressure dro...

Page 2167: ...ative Emission Repair Verification Drive Cycle in this section No GO to E16 E16 TEST FOR CANISTER LEAK Disconnect the EVAP canister inlet elbow from the evaporative emissions canister and plug the EVAP canister inlet elbow Carry out the evaporative emission system leak test Refer to Evaporative Emission System Leak Test in this section Does the EVAP system pass the leak test Yes INSTALL a new EVAP...

Page 2168: ...Refer to Canister Vent Solenoid Closing Procedure in this section Pressurize the system Does the pressure drop Yes INSPECT fuel filler pipe to tank grommet for cuts abrasions or leaks REFER to Section 310 00 for repair procedures No CARRY OUT a leak test REFER to Evaporative Emission System Leak Test in this section If the system passes the leak test CARRY OUT the evaporative emission repair verif...

Page 2169: ...repair verification drive cycle REFER to Evaporative Emission Repair Verification Drive Cycle in this section No GO to F4 F4 TEST FOR BLOCKAGE IN THE FRESH AIR TUBE ON THE FUEL FILLER PIPE ASSEMBLY Disconnect the fresh air tube from the fuel filler pipe assembly Pressurize the EVAP system to 3 48 kPa 14 inches H 2 O Does the pressure drop immediately Yes INSTALL a new fuel filler pipe assembly REF...

Page 2170: ...fication Drive Cycle in this section No GO to F7 F7 TEST FOR BLOCKAGE IN CANISTER VENT SOLENOID Disconnect the canister vent solenoid from the evaporative emissions canister Refer to Evaporative Emission Canister Vent Solenoid in this section Pressurize the EVAP system to 3 48 kPa 14 inches H 2 O Does the pressure drop immediately Yes INSTALL a new canister vent solenoid REFER to Evaporative Emiss...

Page 2171: ... to Evaporative Emission Repair Verification Drive Cycle in this section No GO to F10 F10 TEST FOR PINCHED FUEL VAPOR CONTROL VALVE TUBE Lower the fuel tank 19 05 mm 3 4 inch Connect the Evaporative Emission System Leak Tester to the fuel filler pipe Close the canister vent solenoid Refer to Canister Vent Solenoid Closing Procedure in this section Pressurize the EVAP system to 3 48 kPa 14 inches H...

Page 2172: ...asses the leak test CARRY OUT the evaporative emission repair verification drive cycle REFER to Evaporative Emission Repair Verification Drive Cycle in this section No INSTALL a new fuel filler pipe assembly REFER to Section 310 01 CARRY OUT a leak test REFER to Evaporative Emission System Leak Test in this section If the system passes the leak test CARRY OUT the evaporative emission repair verifi...

Page 2173: ... failure in the diagnostics causing unnecessary repairs 1 Connect the scan tool and select the output test mode 2 If PID monitors are not active select PIDs 3 Select the fuel tank pressure FTP and the volts V parameter identification PID for monitoring 4 Select the ALL OFF mode 5 Close the canister vent solenoid by pushing the START button on the scan tool SECTION 303 13 Evaporative Emissions 2003...

Page 2174: ...ocedure in this section 3 Pressurize the evaporative emission system to 3 48 kPa 14 inches H 2 O 4 Monitor the system for two minutes The system fails the leak test if the pressure falls below 2 0 kPa 8 inches H 2 O 5 Repair any leaks as necessary 6 Repeat the leak test until the system remains above 2 0 kPa 8 inches H 2 O after the two minute test period SECTION 303 13 Evaporative Emissions 2003 ...

Page 2175: ......

Page 2176: ... with three quarters full being the most desirable 3 The evaporative monitor can only operate during the first 30 minutes of engine operation When executing the procedure for this monitor stay in part throttle mode and drive in a smooth fashion to minimize fuel slosh Drive Cycle Preparation NOTE For best results follow each of the following steps as accurately as possible 4 NOTE This step bypasses...

Page 2177: ... be between 15 and 85 NOTE Avoid sharp turns and hills Cruise at 72 to 104 km h 45 to 65 mph for 10 minutes 11 NOTE This step executes the ISC portion of the Secondary Air CCM Bring the vehicle to a stop Idle with the transmission in DRIVE for automatic transmission or NEUTRAL for manual transmission for two minutes Pending Code and EVAP Monitor Bypass Check 12 NOTE This determines if a pending co...

Page 2178: ......

Page 2179: ...Disconnect the battery ground cable For additional information refer to Section 414 01 2 Raise and support the vehicle For additional information refer to Section 100 02 3 Remove the left rear wheel For additional information refer to Section 204 04 4 WARNING Do not smoke or carry lighted tobacco or open flame of any type when working on or around any fuel related component Highly flammable mixtur...

Page 2180: ...P canister with bracket assembly from the vehicle Remove the bolts 8 Disconnect the brace 9 Remove the canister vent solenoid and canister vent solenoid hose assembly 10 Remove the EVAP canister purge outlet tube elbow ...

Page 2181: ...ocedure Carry out a leak test For additional information refer to Evaporative Emission System Leak Test in this section Carry out the evaporative emission repair verification drive cycle For additional information refer to Evaporative Emission Repair Verification Drive Cycle in this section ...

Page 2182: ... fuel vapor or fuel liquid is present in the area Failure to follow these instructions may result in personal injury Disconnect the battery ground cable For additional information refer to Section 414 01 2 Raise and support the vehicle For additional information refer to Section 100 02 3 Remove the RH front wheel For additional information refer to Section 204 04 4 Remove the right front splash sh...

Page 2183: ...uel related component Highly flammable mixtures are always present and may be ignited Failure to follow these instructions may result in personal injury Disconnect the evaporative emission EVAP canister purge outlet tube 8 Disconnect the EVAP return tube 9 Remove the nuts and the EVAP canister purge valve ...

Page 2184: ...em For additional information refer to Evaporative Emission System Leak Test in this section Carry out the evaporative emission repair verification drive cycle For additional information refer to Evaporative Emission Repair Verification Drive Cycle in this section ...

Page 2185: ...ed along with the fuel vapor control valve and the in line fuel tank pressure sensor as a fuel vapor control valve tube assembly For removal and installation of the fuel vapor vent valve refer to Fuel Vapor Control Tube Assembly Valve in this section SECTION 303 13 Evaporative Emissions 2003 Mustang Workshop Manual ...

Page 2186: ... procedure Remove the fuel vapor control valve tube assembly 1 Loosen the fuel vapor vent valve 2 Loosen the fuel vapor control valve 3 Remove the fuel vapor control valve tube assembly 4 NOTE Lubricate all O ring seals with MERPOL O Ring Seal Lubricant or equivalent meeting Ford specification ESE M99B144 B NOTE New grommets are necessary when the fuel vapor control valve tube assembly is removed ...

Page 2187: ...information refer to Evaporative Emission Repair Verification Drive Cycle in this section ...

Page 2188: ...or is repaired along with the fuel vapor vent valve and the fuel vapor control valve as a fuel vapor control valve tube assembly For removal and installation of the fuel vapor control valve refer to Fuel Vapor Control Tube Assembly Valve in this section SECTION 303 13 Evaporative Emissions 2003 Mustang Workshop Manual ...

Page 2189: ...02 3 Remove the RH front wheel For additional information refer to Section 204 04 4 Remove the RH front splash shield 1 Remove the three screws 2 Remove the five pin type retainers 5 Remove the evaporative emission test port by disconnecting at the EVAP canister purge outlet tube junction 6 To install reverse the removal procedure SECTION 303 13 Evaporative Emissions 2003 Mustang Workshop Manual ...

Page 2190: ...rmation refer to Evaporative Emission System Leak Test in this section Carry out the evaporative emission repair verification drive cycle For additional information refer to Evaporative Emission Repair Verification Drive Cycle in this section ...

Page 2191: ...mission Canister Vent Solenoid Removal and Installation 1 Remove the canister vent solenoid For additional information refer to Evaporative Emission Canister in this section SECTION 303 13 Evaporative Emissions 2003 Mustang Workshop Manual ...

Page 2192: ...ture ECT sensor 4 6L 4V 24 18 Heated oxygen sensors HO2S 41 30 Catalyst monitor sensors 41 30 Crankshaft position CKP sensor bolts 3 8L 6 53 Crankshaft position CKP sensor bolts 4 6L 10 89 Power steering reservoir bolts 10 89 Camshaft position CMP sensor bolt 4 6L 10 89 PCM connector to module bolt 6 53 Idle air control IAC valve bolts 10 89 Camshaft synchronizer housing bolt 25 18 Throttle positi...

Page 2193: ......

Page 2194: ... crankshaft position engine rpm engine load manifold pressure atmospheric barometric pressure engine coolant temperature The throttle position sensor sends the powertrain control module a signal indicating the throttle plate angle is the main input to the powertrain control module from the driver The idle air control valve controls bypass air around the throttle plate at low speeds is controlled b...

Page 2195: ...temperature sensor sends the powertrain control module a signal indicating the temperature of the air entering the engine The heated oxygen sensor has the ability to create a voltage signal depending on exhaust oxygen content provides feedback information to the powertrain control module used to calculate fuel delivery The rear catalyst monitor sensor monitors oxygen content after the oxygen flows...

Page 2196: ......

Page 2197: ... Solenoid and Actuator The Supercharger bypass vacuum solenoid will bleed off boost under the following conditions heavy engine misfire engine coolant over temperature loss of intercooler fluid pump failure This prevents damage that can occur if boost were allowed under these conditions The solenoid is located on the upper LH side of the engine The solenoid uses engine vacuum to operate a actuator...

Page 2198: ......

Page 2199: ...DIAGNOSIS AND TESTING Electronic Engine Controls Refer to the Powertrain Control Emissions Diagnosis PC ED manual SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2200: ...sor Cobra Removal and Installation 1 Disconnect the temperature manifold absolute pressure T MAP sensor electrical connector 2 Remove the bolts and the T MAP sensor 3 To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2201: ......

Page 2202: ...y ground cable For additional information refer to Section 414 01 2 Remove the camshaft position CMP sensor Disconnect the connector Remove the bolts and the sensor Installation 1 To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2203: ...dditional information refer to Section 414 01 2 Remove the bolts and position aside the power steering pump reservoir 3 Remove the camshaft position CMP sensor Disconnect the connector Remove the bolt and the sensor 4 To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2204: ......

Page 2205: ...ld For additional information refer to Section 303 01A 4 Remove the fuel injector supply manifold For additional information refer to Section 303 04A 5 Remove the coolant bypass tube For additional information refer to Section 303 03A 6 Remove the bolt and heater water inlet tube at the back of the lower intake 7 Remove the two stud bolts and one bolt Position the actuator aside 8 Disconnect the l...

Page 2206: ... driver plate until the levers make contact with the set screws then rotate the motor until the motor bracket bolt holes line up with the tapped holes in the lower intake manifold NOTE Discard O ring and install a new O ring on the heater inlet tube Lubricate the O ring with engine coolant prior to installation To install reverse the removal procedure ...

Page 2207: ...y ground cable For additional information refer to Section 414 01 2 Remove the crankshaft position CKP sensor Disconnect the connector Remove the bolts and the sensor Installation 1 To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2208: ...refer to Section 414 01 2 Remove the A C compressor For additional information refer to Section 412 03 3 Remove the crankshaft position CKP sensor Disconnect the connector Remove the bolt and remove the sensor Installation 1 To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2209: ... information refer to Section 414 01 2 Remove the RH front door scuff plate 3 Remove the RH cowl side trim panel Remove the pin type retainer Remove the panel 4 Disconnect the connectors and position them aside 5 Remove the bolts and the bracket SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2210: ...6 Loosen the bolt and remove the connector 7 Remove the bolt and the powertrain control module PCM Installation 1 To install reverse the removal procedure ...

Page 2211: ......

Page 2212: ...isconnect the battery ground cable For additional information refer to Section 414 01 2 Remove the throttle position TP sensor Disconnect the connector Remove the screws and remove the sensor Installation 1 To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2213: ......

Page 2214: ...sor Cobra Removal and Installation 1 Disconnect the throttle position TP sensor electrical connector 2 Remove the bolts and the TP sensor 3 To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2215: ......

Page 2216: ...the air intake scoop bracket For additional information refer to Section 303 12 2 Disconnect the throttle position TP sensor electrical connector 3 Remove the bolts and the TP sensor 4 To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2217: ......

Page 2218: ...nal information refer to Section 414 01 2 NOTE Discard the idle air control IAC valve gasket Remove the IAC valve Disconnect the connector Remove the two bolts the IAC valve and the gasket Installation 1 To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2219: ......

Page 2220: ...formation refer to Section 414 01 2 NOTE Discard the idle air control IAC valve gasket Remove the IAC valve Disconnect the connector Disconnect the hose Remove the bolts the IAC valve and the gasket Installation 1 To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2221: ......

Page 2222: ...tallation 1 Disconnect the idle air control IAC valve electrical connector 2 Remove the bolts the IAC valve and the gasket 3 NOTE Install a new gasket if necessary To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2223: ......

Page 2224: ...For additional information refer to Section 303 12 2 Disconnect the idle air control IAC valve electrical connector 3 Remove the bolts the IAC valve and the gasket 4 NOTE Install a new gasket if necessary To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2225: ......

Page 2226: ...t the battery ground cable For additional information refer to Section 414 01 2 Disconnect the cylinder head temperature sensor connector 3 Remove the CHT sensor Installation 1 To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2227: ......

Page 2228: ...tion refer to Section 414 01 2 Partially drain the cooling system For additional information refer to Section 303 03A 3 Disconnect the engine coolant temperature ECT sensor 12A648 connector 4 Remove the ECT sensor Installation 1 To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2229: ......

Page 2230: ...ion refer to Section 303 03A 2 Disconnect the engine coolant temperature ECT sensor electrical connector 3 Remove the ECT sensor 4 To install reverse the removal procedure Apply sealant to the ECT sensor threads SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual Material Item Specification Pipe Sealant with Teflon D8AZ 19554 A WSK M2G350 A2 ...

Page 2231: ......

Page 2232: ...ne cooling system For additional information refer to Section 303 03A 3 Disconnect the engine coolant temperature ECT sensor electrical connector 4 Remove the ECT sensor 5 To install reverse the removal procedure Apply sealant to the ECT sensor threads SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual Material Item Specification Pipe Sealant with Teflon D8AZ 19554 A WSK M2G350...

Page 2233: ......

Page 2234: ...ible failure to the mass air flow sensor may occur 1 Disconnect the battery ground cable For additional information refer to Section 414 01 2 Remove the air cleaner and duct assembly For additional information refer to Section 303 12 3 Release the four tabs and remove the mass air flow MAF sensor 4 Disconnect the connector 5 Remove the mass air flow sensor MAF Remove the nuts and the MAF sensor SE...

Page 2235: ...Installation 1 To install reverse the removal procedure ...

Page 2236: ...or possible failure to the mass air flow sensor may occur 1 Disconnect the battery ground cable For additional information refer to Section 414 01 2 Remove the air cleaner outlet tube For additional information refer to Section 303 12 3 Remove the mass air flow sensor MAF Disconnect the connector Remove the four nuts and the MAF sensor Installation 1 To install reverse the removal procedure SECTIO...

Page 2237: ......

Page 2238: ...val and Installation 1 Disconnect the intake air temperature IAT sensor 2 Disconnect the breather hose 3 Disconnect the vacuum hose 4 Loosen the clamps and remove the air cleaner outlet pipe SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2239: ...ust be repaired as a complete assembly Do not damage the sensing element internal to housing or possible failure to the mass air flow sensor can occur Remove the mass air flow sensor Disconnect the MAF sensor electrical connector Remove the bolts and the MAF sensor 6 To install reverse the removal procedure ...

Page 2240: ......

Page 2241: ...or possible failure to the mass air flow sensor may occur 1 Disconnect the battery ground cable For additional information refer to Section 414 01 2 Remove the air cleaner outlet tube For additional information refer to Section 303 12 3 Remove the mass air flow sensor MAF Disconnect the connector Remove the four nuts and the MAF sensor Installation 1 To install reverse the removal procedure SECTIO...

Page 2242: ......

Page 2243: ...erter Y pipe The left side HO2S is shown the right side is similar Disconnect the HO2S electrical connector 4 NOTE If necessary lubricate the heated oxygen sensors with penetrating and lock lubricant to assist in removal Using the special tool remove the HO2S from the dual converter Y pipe 5 To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Ma...

Page 2244: ......

Page 2245: ...verter Y pipe downstream from the catalyst The left side catalyst monitor sensor is shown the right side is similar Disconnect the connector 4 NOTE If necessary lubricate the sensors with penetrating and lock lubricant to assist in removal Using the special tool remove the catalyst monitor sensors from the dual converter Y pipe SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual...

Page 2246: ...5 To install reverse the removal procedure ...

Page 2247: ...battery ground cable For additional information refer to Section 414 01 2 Disconnect the connector 3 Remove the bolt and the clutch pedal position CPP switch Installation 1 To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2248: ......

Page 2249: ...he fuel lines or fuel system components the fuel system pressure must be relieved Failure to follow these instructions may result in personal injury Mach I 1 Remove the air intake scoop For additional information refer to Section 303 12 All engines 2 Relieve the fuel pressure For additional information refer to Section 310 00 3 NOTE The 4 6L 4V Cobra engine is shown the other engines are similar D...

Page 2250: ...Installation 1 Inspect the O rings and install new O rings if necessary 2 NOTE Lubricate the new O rings with clean engine oil to aid installation To install reverse the removal procedure ...

Page 2251: ...supercharger bypass vacuum solenoid 1 Disconnect the vacuum hoses 2 Disconnect the electrical connector 3 Unclip the supercharger bypass vacuum solenoid from the vacuum accessory bracket 2 To install reverse the removal procedure SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2252: ...s vacuum solenoid and the differential pressure feedback EGR system 2 Disconnect the vacuum hoses from the differential pressure feedback EGR system 3 Disconnect the vacuum hoses from the supercharger bypass vacuum solenoid and the actuator 4 Disconnect the vacuum hoses from the EGR vacuum regulator solenoid SECTION 303 14 Electronic Engine Controls 2003 Mustang Workshop Manual ...

Page 2253: ...um accessory bracket mounting nut 6 Remove the mounting bolts and the vacuum accessory bracket 7 Remove the actuator mounting bolts 8 Align the actuator rod with the slot in the actuator linkage and remove the actuator ...

Page 2254: ...rrectly adjust the actuator will result in incorrect operation of the supercharger assembly Install the actuator adjustment tool onto the actuator making sure the tool is correctly attached to the actuator rod rotate the actuator into position until the rod engages the lever 2 Install the actuator Align the actuator rod with the slot in the linkage 3 Install the actuator bolts ...

Page 2255: ...e vacuum accessory bracket and the mounting bolts 6 Install the vacuum accessory bracket mounting nut 7 Connect the vacuum hoses to the EGR vacuum regulator solenoid 8 Connect the vacuum hoses to the supercharger bypass vacuum solenoid and the actuator ...

Page 2256: ...m hoses to the differential pressure feedback EGR system 10 Connect the electrical connectors to the EGR vacuum regulator solenoid the supercharger bypass vacuum solenoid and the differential pressure feedback EGR system ...

Page 2257: ......

Page 2258: ...13 2L 13 9 quarts 4 6L engine 12 0L 12 8 quarts Fluid Filter Inline Transmission Fluid Filter Kit XC3Z 7B155 AA Inline Transmission Fluid Filter XC3Z 7B155 BA Lubricant Ford Multi Purpose Grease D0AZ 19584 AA ESB M1C93 B Torque Converter End Play Item Specification New or remanufactured 0 355 1 04 mm 0 014 0 074 in Used 0 355 1 87 mm 0 014 0 074 in Band and Clutch Application Chart Gear Overdrive ...

Page 2259: ... Light throttle 1 2 10 14 16 23 TP voltage 2 3 18 22 29 35 1 25 volts 3 4 34 37 55 60 Closed throttle 4 3 22 25 35 40 3 2 12 16 19 26 2 1 11 7 18 11 Wide open throttle 1 2 36 44 58 71 2 3 75 83 121 134 3 2 70 113 2 1 33 53 Shift Speeds 4 6L 2V HO 3 27 1 Axle Ratio Throttle Position Shift MPH Km H Light throttle 1 2 9 12 14 19 TP voltage 2 3 14 18 23 29 1 25 volts 3 4 36 38 58 61 Closed throttle 4 ...

Page 2260: ...6 40 58 64 2 3 74 70 119 112 3 2 67 108 2 1 28 45 Shift Speeds 3 8L 3 08 1 Axle Ratio Throttle Position Shift MPH Km H Light throttle 1 2 6 10 10 16 TP voltage 2 3 16 20 26 32 1 25 volts 3 4 38 42 61 68 Closed throttle 4 3 34 28 55 45 3 2 16 13 26 21 2 1 9 7 14 11 Wide open throttle 1 2 38 45 61 72 2 3 72 76 116 122 3 2 71 114 2 1 31 50 Sensor Resistance Readings Component Resistance ohms SSA 20 3...

Page 2261: ...25 0 060 0 064 1 880 1 981 0 074 0 078 2 235 2 337 0 088 0 092 2 591 2 692 0 102 0 106 Reverse Clutch Pack Item Specification mm inch Clearance 1 27 1 94 mm 0 050 0 076 in Snap ring thickness 1 524 1 625 0 060 0 064 1 880 1 981 0 074 0 078 2 235 2 337 0 088 0 092 2 591 2 692 0 102 0 106 Direct Clutch Pack Item Specification mm inch Clearance 1 5748 21 59 0 062 0 85 Snap ring thickness 1 270 1 372 ...

Page 2262: ...ntrol valve body separator plate bolts 10 89 Manual lever shaft nut 33 24 Manual lever shaft outer nut 33 24 Fluid cooler line case fittings 21 15 Pressure tap plugs 12 9 Rear driveshaft bolts 112 83 Starter bolts 25 18 TCC solenoid bolt 10 89 Torque converter drain plug 12 9 Torque converter nuts 37 27 Digital transmission range TR sensor bolts 9 80 Transmission bell housing bolts 47 35 Vehicle s...

Page 2263: ...Transmission linkage 23 17 Shift cable bracket 14 10 Transmission test plate bolts 10 89 ...

Page 2264: ...hift Torque converter clutch control Line pressure controls The transmission uses Ravigneaux style double pinion gearset with two bands one one way roller clutch one mechanical diode and four friction clutches to produce four forward gears and Reverse 4R70W Automatic Transmission SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual ...

Page 2265: ...ntification refer to the code in the space marked TR For model service ID level or build date information refer to the transmission service ID tag located on the transmission case Identification Tag SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Item Part Number Description 1 Model number 2 Assembly number 3 Serial number 4 Model and serial number ...

Page 2266: ... Reverse In the REVERSE position the vehicle can be operated in a rearward direction at a reduced gear ratio engine braking will occur Neutral In the NEUTRAL position there is no powerflow through the transmission the output shaft is not held and is free to turn the engine can be started Overdrive Overdrive is the normal position for most forward driving The OVERDRIVE position provides Automatic s...

Page 2267: ...y and release Improved traction and engine braking on slippery roads Engine braking for descending steep grades First Position If this position is selected at normal road speeds the transmission will shift into second gear then into first when the vehicle reaches a speed below approximately 45 km h 28 mph This position provides First gear operation only Engine braking for descending steep grades ...

Page 2268: ...stdown The coastdown downshift occurs when the vehicle is coasting down to a stop Torque Demand The torque demand downshift occurs automatically during part throttle acceleration when the demand for torque is greater than the engine can provide at that gear ratio If applied the transmission will disengage the TCC to provide added acceleration Kickdown For maximum acceleration the driver can force ...

Page 2269: ...DESCRIPTION AND OPERATION Disassembled Views 4R70W Automatic Transmission Disassembled View SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual ...

Page 2270: ...del dependent 2 391855 S100 Plug converter drain 1 8 27 Dryseal model dependent 3 7A103 Pump assembly front 4 7A248 Seal assembly front pump 5 7A248 Seal front pump 6 7B258 Bushing front pump 7 N605789 S100 Bolt M8 1 25 x 35 hex head 7 attaches 7A103 to 7005 ...

Page 2271: ... friction 23 7B066 Plate intermediate clutch pressure 24 7F196 Band assembly overdrive 25 391267 S Ring 3 21 64 retains type SU external retains 7F262 to 7F215 26 7F271 Clutch assembly intermediate one way clutch 27 7D044 Drum assembly reverse clutch 28 7D403 Seal reverse clutch piston outer 29 7D402 Piston assembly reverse clutch 30 7D404 Seal reverse clutch piston inner 31 7D256 Ring reverse clu...

Page 2272: ...ward clutch sun gear No 5 59 388501 S Retaining ring center support 7 7 92 60 7A399 Gear assembly forward clutch sun 61 7F277 Spring case to planet support 62 7A130 Support assembly planetary gear 63 7A089 OWC cage spring and roller assembly planetary 64 7A398 Planetary assembly model dependent 65 7D095 Band assembly reverse 66 377437 S Retaining ring 0 58 thick locates reverse band during assembl...

Page 2273: ...aches 7A039 to 7005 model dependent 94 7A039 Extension housing assembly model dependent 95 Bushing extension housing part of 7A039 96 7052 Seal assembly extension housing model dependent 97 390318 S100 Pipe plug 1 8 27 Dryseal tapered 5 req d 98 7F295 Pin overdrive band anchor 99 388142 S Pin reverse band anchor part of 7005 100 7034 Vent assembly case 101 N605771 S427 Bolt M6 1 0 x 14 hex head at...

Page 2274: ... 7A115 to 7A256 126 7H188 Piston assembly overdrive servo 127 7F201 Spring overdrive servo piston 128 7F203 Rod overdrive servo actuating part of 7H188 129 7H179 Washer backup overdrive servo part of 7H188 130 7G277 Spring overdrive cushion spring part of 7H188 131 7F200 Piston assembly overdrive servo part of 7H188 132 97411 S Ring retaining part of 7H188 133 7384 Ring 2 85 retaining type TVP H i...

Page 2275: ...al assembly fluid 159 7A191 Gasket transmission pan 160 7A194 Pan transmission 161 N605785 S1036 Bolt M8 1 25 x 18 hex flange head 14 attaches 7A194 to 7005 162 7L027 Magnet ceramic case part of 7A194 163 N808947 S1300 Bolt M8 1 25 x 46 hex shoulder pilot 2 attaches 7C034 to 7A100 164 N807179 S1000 Bolt M6 1 0 x 52 hex flange head 12 attaches 7A100 to 7005 165 7H111 Retainer solenoid 166 7E195 Bal...

Page 2276: ...7Z136 Seal 0 489 x 0 070 O ring 178 7Z484 Seal 0 176 x 0 070 O ring A Intermediate clutch assembly B Intermediate one way clutch C Reverse clutch assembly D Forward clutch assembly E Direct clutch assembly ...

Page 2277: ... bearing and race assembly No 4 5 7F244 Forward clutch sun gear bearing and race assembly No 5 6 7F241 Planet assembly bearing and race No 6 7 7F243 7F237 Direct clutch inner bearing race assembly No 7 and direct clutch inner bearing support No 7 8 7F240 Direct clutch outer bearing and race assembly No 8 9 7F242 Outer bearing and race assembly rear No 9 10 Extension bushing part of 7A039 11 7025 C...

Page 2278: ... front 17 7A132 Planetary support bushing 18 7F218 Reverse clutch drum bushing rear 19 7B261 Front pump support bushing 20 7F217 Reverse clutch drum bushing front 21 7B258 Front pump bushing 22 7B261 Front pump support bushing ...

Page 2279: ...ION Seals Rings and Gasket Locator SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Item Part Number Description 1 7A248 Front pump seal assembly 2 7A248 Front pump seal 3 7A136 Front pump gasket ...

Page 2280: ...6 7F273 Output shaft to case seal 3 req d 17 7B497 Input shaft seal 2 req d 18 7C099 Forward clutch piston inner seal 19 7A548 Forward clutch piston outer seal 20 7B498 Manual control lever seal assembly 21 7D403 Reverse clutch piston outer seal 22 7D404 Reverse clutch piston inner seal 23 7F224 Intermediate clutch piston outer seal 24 7F225 Intermediate clutch piston inner seal 25 391308 S Fill t...

Page 2281: ......

Page 2282: ...umber Description 1 7902 Torque converter 2 7B164 Intermediate clutch friction 3 7B164 Reverse clutch friction 4 7B164 Forward clutch friction 5 7B164 Direct clutch friction 6 7F207 Forward clutch cylinder and shaft 7 7F351 Shaft intermediate stub 8 7060 Output shaft 9 7A089 Planetary one way clutch 10 7D095 Reverse clutch band 11 7F196 Overdrive band 12 7A089 Intermediate one way clutch ...

Page 2283: ......

Page 2284: ...er transferring rotation to the geartrain through the input shaft The reactor redirects fluid going back into the impeller allowing for torque multiplication The clutch and damper assembly dampens powertrain torsional vibration and provides a direct mechanical connection for improved efficiency Power is transmitted from the torque converter to the planetary gearsets and other components through th...

Page 2285: ...4 Impeller part of 7902 5 Fluid motion 6 Transmission input rotation 7 Input shaft 8 Engine rotation ...

Page 2286: ...ches one roller one mechanical diode four friction clutches Planetary Gearset The planetary gearset in the transmission is a Ravigneaux type set consisting of the following components forward clutch sun gear reverse clutch sun gear a pinion carrier long and short pinions output ring gear Components are held or driven to produce forward and reverse gear ratios Input Shaft The forward clutch cylinde...

Page 2287: ...m the input shaft to the planet carrier through the direct clutch during third and fourth gear operation Output Shaft The output shaft provides torque to the driveshaft and rear axle assembly It is driven by the ring gear of the planetary gearset ...

Page 2288: ...these ranges Band Low and Reverse The low and reverse band holds the pinion carrier in reverse The reverse band also applies in manual 1 position to provide engine braking Clutch Intermediate Intermediate Clutch Disassembled View SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Item Part Number Description 1 7F196 Overdrive band assembly 2 7D044 Reverse clutch drum asse...

Page 2289: ...r Item Part Number Description 1 7B442 Intermediate clutch plates steel 2 7B066 Intermediate clutch pressure plate 3 391267 S Retaining ring 4 7A089 Intermediate one way clutch assembly 5 7B164 Intermediate clutch plates friction Item Part Number Description 1 7F207 Forward clutch cylinder and input shaft assembly 2 7E085 Rear clutch pressure plate spring 3 7B442 Forward clutch plate external spli...

Page 2290: ... 1 7F351 Intermediate stub shaft 2 7A398 Planetary assembly 3 7D483 Direct clutch pressure plate retaining ring select fit 4 7B066 Direct clutch pressure plate 5 7B442 Direct clutch plates external splined steel 6 7B164 Direct clutch plates internal splined friction 7 7F283 Direct clutch cylinder assembly Item Part Number Description 1 7D044 Reverse clutch drum assembly ...

Page 2291: ... 7B442 Reverse clutch plate external splined steel 3 7B066 Reverse clutch pressure plate rear 4 7D483 Reverse clutch pressure plate retaining ring select fit 5 7F207 Forward clutch cylinder and input shaft assembly 6 7A019 Reverse clutch sun gear assembly 7 7B164 Reverse clutch plate internal splined friction Item Part Number Description 1 7A130 Planetary gear support assembly 2 7A089 Planetary on...

Page 2292: ...th the intermediate friction clutch to hold the reverse clutch drum and reverse sun gear stationary in second gear during acceleration The intermediate one way clutch freewheels in third gear and during coasting in second gear D and D ranges ...

Page 2293: ...Manual Item Part Number Description 1 7A106 Front pump body assembly 2 7005 Case assembly 3 7A194 Transmission pan 4 7A191 Transmission pan gasket 5 7A098 Fluid filter and seal assembly 6 7A100 Main control assembly 7 7A108 Front pump support assembly 8 7D273 Fluid tube connector assembly 2 req d Item Part Number Description ...

Page 2294: ...r All fluid drawn from the transmission pan by the pump passes through the filter The filter and its accompanying seal are part of the fluid path from the sump pan to the fluid pump Main Control The main control valve body houses three electronic solenoids two shift solenoids one torque converter clutch solenoid TCC solenoid Accumulators 1 Outer rotor part of 7A103 2 Inner rotor part of 7A103 3 Ou...

Page 2295: ...he 2 3 shift by absorbing some of the direct clutch pressure Forward clutch pressure is applied to the top side of the 2 3 accumulator piston holding the piston down until clutch pressure is high enough to overcome it The middle section of the piston is exhausted to the sump Item Part Number Description 1 7F284 Spring 1 2 shift accumulator model dependent 2 7F251 Piston 1 2 shift accumulator 3 7F2...

Page 2296: ......

Page 2297: ...ion is controlled by the powertrain control module PCM Many input sensors provide information to the PCM The PCM then controls actuators which determine transmission operation Air Conditioning A C Clutch An electromagnetic clutch is energized when the clutch cycling pressure switch closes The switch is located on the suction accumulator drier The closing of the switch completes the circuit to the ...

Page 2298: ...fts from first through fourth gears or first through third gears only The PCM energizes the transmission control indicator lamp TCIL when the switch is off The TCIL indicates overdrive cancel mode activated lamp on When the TCIL is flashing it indicates electronic pressure control EPC circuit shorted or a monitored sensor failure Throttle Position TP Sensor The throttle position TP sensor is a pot...

Page 2299: ... shift schedule is compensated when the transmission fluid temperature is cold The PCM also inhibits TCC operation at low transmission fluid temperatures and corrects electronic pressure control Vehicle Speed VSS Sensor The source of vehicle speed VSS is model dependent Possible sources of vehicle speed input are anti lock brake sensor ABS a gear driven vehicle speed sensor VSS or an output shaft ...

Page 2300: ...engine control ...

Page 2301: ...ns Use the Diagnostic Flow Chart as a guide and follow the steps as indicated Preliminary Inspection Know and understand the customer s concern Verify the concern by operating the vehicle Check the fluid levels and condition Check for non factory add on items Check shift linkages for proper adjustment Check TSBs and OASIS messages regarding the concern Diagnostics Carry out on board diagnostic pro...

Page 2302: ......

Page 2303: ...Y OUT drive cycle test No GO to Step 4 3 Did the continuous test memory codes reappear Yes REPAIR all continuous test memory codes FOLLOW the pinpoint tests REFER to the Powertrain Control Emissions Diagnosis PC ED manual then the transmission reference manual then this workshop manual then GO to Step 4 No GO to Step 4 4 Is the concern repaired Yes CARRY OUT the final quick test to verify that no ...

Page 2304: ...chanical routine to diagnose the concern then GO to Step 7 7 Is the concern repaired Yes CARRY OUT the final quick test to verify that no diagnostic trouble codes are present CLEAR memory codes No Get assistance from technical hotline ...

Page 2305: ... carrying out the appropriate procedures The following procedures must be used when verifying customer concerns for the transmission Determine Customer Concern NOTE Some transmission conditions can cause engine concerns An electronic pressure control short circuit can cause engine misfiring The torque converter clutch not disengaging will stall the engine Determine customer concerns relative to ve...

Page 2306: ...gh each gear and allow engagement of each gear Place the transmission range selector lever in the P position 2 Wipe the fluid level indicator cap and remove the indicator 3 Wipe the indicator with a clean cloth 4 Install the indicator back in the filler tube until it is fully seated then remove the indicator The fluid level should be within the normal operating temperature range High Fluid Level A...

Page 2307: ...ial tissue and allow the fluid to drip onto the facial tissue and examine the stain 4 If evidence of solid material is found the transmission fluid pan should be removed for further inspection 5 If the stain is a foamy pink color this may indicate coolant in the transmission The engine cooling system should also be inspected at this time 6 If fluid contamination or transmission failure is confirme...

Page 2308: ...ccording to the driving conditions and obey all traffic laws The shift point road test and torque converter operation tests provide diagnostic information on transmission shift controls and torque converter operation SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual ...

Page 2309: ...ing on vehicle speed Torque converter clutch should disengage and then reapply 6 With the transmission in D position and speed above 80 km h 50 mph and less than half throttle move the transmission range selector lever from D position to manual 2 position and remove pressure from the accelerator pedal Transmission should immediately downshift into second gear With vehicle remaining in manual 2 pos...

Page 2310: ...t MPH Km H Light throttle 1 2 6 10 10 16 TP voltage 2 3 18 22 29 35 1 25 volts 3 4 28 30 45 48 Closed throttle 4 3 24 22 39 35 3 2 14 12 22 19 2 1 6 8 10 13 Wide open throttle 1 2 36 40 58 64 2 3 74 70 119 112 3 2 67 108 2 1 28 45 Shift Speeds 3 8L 3 08 1 Axle Ratio Throttle Position Shift MPH Km H Light throttle 1 2 6 10 10 16 TP voltage 2 3 16 20 26 32 1 25 volts 3 4 38 42 61 68 Closed throttle ...

Page 2311: ......

Page 2312: ...ymptom in this section Use the Diagnosis by Symptom Index to locate the appropriate routine that best describes the symptom s The routine will list all possible components that may cause or contribute to the symptom Check each component listed diagnose and repair as required before changing the torque converter Torque Converter Operation Test This test verifies that the torque converter clutch con...

Page 2313: ...ce EGR valve valve may let in too much exhaust gas and cause engine to run lean vacuum leak engine will not get correct air fuel mixture MAP MAF sensor incorrect air fuel mixture HO2S sensor too rich lean air fuel mixture fuel pressure may be too low engine mounts loose damaged mounts can cause vibration concerns axle joints check for vibration Torque Converter Road Evaluation Form 1 Does the Torq...

Page 2314: ... No GO to Step 5 5 Does the problem occur in coast steady speed or reverse range Yes Not torque converter clutch shudder REFER to Section 100 04 and Diagnosis By Symptom Noise Vibration Routine 254 354 in this section for further diagnosis No GO to Step 6 6 Does vibration occur during extended light brake application Yes Not torque converter clutch shudder REFER to Section 100 04 Section 206 00 an...

Page 2315: ......

Page 2316: ...Shift Linkage Check Check for a misadjustment in shift linkage by matching the detents in the transmission range selector lever with those of the manual lever in the transmission If they match the misadjustment is in the indicator Do not adjust the shift linkage Hydraulic leakage at the manual control valve can cause delay in engagements and or slipping while operating if the linkage is not correc...

Page 2317: ......

Page 2318: ...t Plate Transmission 307 246 T92P 7006 A Alignment Gauge TR Sensor 307 351 T97L 70010 A Breakout Box EEC V Control System 418 049 T94L 50 EEC V or equivalent MLP TR Cable 418 F107 007 00111 or equivalent Worldwide Diagnostic System WDS 418 F224 New Generation STAR NGS Tester 418 F052 or equivalent scan tool Transmission Tester 307 F016 007 00130 or equivalent Trans Tester TR MLP Overlay ...

Page 2319: ...d the Powertrain Control Emissions Diagnosis PC ED manual These quick tests should be used to diagnose the powertrain control module PCM and should be carried out in order Quick Test 1 0 Visual Inspection Quick Test 2 0 Set Up Quick Test 3 0 Key On Engine Off KOEO Quick Test 4 0 Continuous Memory Quick Test 5 0 Key On Engine Running KOER Special Test Mode Wiggle Test Output Test Mode PCM Reset Mod...

Page 2320: ...Oxygen Sensor Monitor Mode ...

Page 2321: ... input source is applicable for their vehicle application The following are potential vehicle speed sources anti lock braking system ABS output shaft speed OSS sensor vehicle speed sensor The vehicle requirements MUST BE MET when SENDING the OSC value Refer to individual test modes for vehicle requirements If the vehicle requirements are NOT MET when SENDING the OSC value an ERROR MESSAGE will app...

Page 2322: ... BENCH MODE operates ONLY when the digital TR sensor is operational and no digital TR sensor DTCs are present the vehicle speed input is operational and no VSS sensor DTCs are present the transmission range selector lever is in P the key is ON the engine is OFF OSC Command Values OFF turns solenoid OFF ON turns solenoid ON XXX cancels OSC value sent SEND sends the values to PCM BENCH MODE Procedur...

Page 2323: ...PC pressure to 517 kPa 75 psi 90 sets EPC pressure to 620 kPa 90 psi To carry out an EPC BENCH MODE pressure functionality test install a pressure gauge in the EPC port The following requirements are required to carry out this test VSS and digital TR sensor operational No VSS and digital TR sensor DTCs Transmission range selector lever in P Key ON Engine ON Engine speed at least 1 500 rpm for accu...

Page 2324: ...technician is required to meet before being allowed to operate OSC The recommended procedure when using the DRIVE MODE is to control one parameter at a time The DRIVE MODE allows the technician to carry out the following functions on the transmission GR_CM allows upshifts or downshifts TCC engages or disengages the torque converter clutch EPC increases decreases EPC pressure GR_CM in DRIVE MODE Th...

Page 2325: ...all selected PIDs during test Select Parameters GR_CM Select Value 1 4 Press SEND to send command Re Select Value 1 4 Press SEND to send command Select XXX to cancel at any time Press SEND TCC in DRIVE MODE This OSC function is used to test whether the torque converter clutch is engaging and disengaging correctly The OSC functions for the TCC parameter allows the technician to choose the following...

Page 2326: ... ON XXX cancels OSC value sent SEND sends the values to PCM Drive Mode Procedures for TCC Follow operating instructions from the scan tool menu screen Select Output State Control Select Trans Drive Mode Select PIDs to be monitored Monitor all selected PIDs during test Select Parameters TCC Select ON to turn solenoid ON Press SEND to send command ON Select OFF to turn solenoid OFF Press SEND to sen...

Page 2327: ...al and no digital TR sensor DTCs are present the vehicle speed sensor is operational and no VSS sensor DTCs are present the transmission range selector lever is in O D the pressure gauge is installed the key is ON the engine is ON the vehicle speed is greater than 3 2 km h 2 mph the OSC value for EPC must be greater than what the PCM commands see EPC PID OSC Command Values 00 sets EPC pressure to ...

Page 2328: ...eter must be monitored Additional PIDs should be monitored to help the technician adequately diagnose the transmission The following is a list of OSC parameters and their corresponding PID To confirm that the OSC substitution occurred SEND the OSC value and monitor the corresponding PID value If no ERROR MESSAGE was received and the value of the corresponding PID remains the same as the value sent...

Page 2329: ......

Page 2330: ... of 20 seconds 7 Repeat steps 4 through 6 at least five times 8 Carry out Quick Test and record continuous DTCs If the DTCs are still present refer to the Diagnostic Trouble Code Chart Repair all non transmission DTCs first as they can directly affect the operation of the transmission Repeat the Quick Test and the Road Test to verify the correction Erase the DTCs carry out the Drive Cycle Test and...

Page 2331: ...d their condition Check the PCM sensors and actuators for damage Refer to the Powertrain Control Emissions Diagnosis PC ED manual NOTE If a concern still exists after electrical diagnosis has been carried out refer to Diagnosis By Symptom in this section If DTCs appear while carrying out the on board diagnostics refer to the Diagnostic Trouble Code Charts for the appropriate repair procedure Prior...

Page 2332: ...r soft shifts REFER to the Powertrain Control Emissions Diagnosis PC ED manual P0114 IAT IAT out of on board diagnostic range IAT temperature higher or lower than expected during KOEO and KOER Rerun on board diagnostic at normal operating temperature REFER to the Powertrain Control Emissions Diagnosis PC ED manual P0117 ECT ECT indicates 125 C 257 F Voltage drop across ECT exceeds scale set for te...

Page 2333: ...an invalid pattern in TR_D Condition caused by a short to ground or an open in TR4 TR3A TR2 and or TR1 circuits This DTC cannot be set by an incorrectly adjusted digital TR sensor Increase in EPC pressure harsh shifts Defaults to D or D for all gear positions In D position trans stuck in D or manual 2 Go To Pinpoint Test C P0707 Digital TR sensor wiring PCM Digital TR sensor circuit below minimum ...

Page 2334: ... a loss of OSS signal during operation Harsh shifts abnormal shift schedule no torque converter clutch activation Go To Pinpoint Test E P0721 OSS OSS sensor signal noisy PCM has detected an erratic OSS signal Harsh shifts abnormal shift schedule no torque converter clutch engagement Go To Pinpoint Test E P0722 OSS wiring Insufficient input from OSS PCM has detected a loss of OSS signal Harsh shift...

Page 2335: ...age drop across solenoid Circuit open or shorted or PCM driver failure during on board diagnostic Incorrect gear depending on condition mode and manual lever position See Solenoid Off On Chart Flashing Transmission Control Indicator Lamp TCIL Go To Pinpoint Test A P0751 SSA wiring PCM Shift solenoid A functional failure Mechanical or hydraulic failure of the shift solenoid Incorrect gear selection...

Page 2336: ... or internal parts 2 3 shift error Engine rpm drop not detected when 2 3 shift was commanded by PCM Incorrect gear selection depending on failure or mode and manual lever position Shift errors may also be due to other internal transmission concerns stuck valves damaged friction material REFER to Solenoid Operation Chart Go To Pinpoint Test A P0783 b SSA SSB or internal parts 3 4 shift error Engine...

Page 2337: ...t cycled during KOER Failed OFF or not connected torque converter clutch will not engage at less than 1 3 throttle Failed OFF or not connected torque converter clutch will not disengage when brake is applied REFER to the Powertrain Control Emissions Diagnosis PC ED manual P0740 TCC wiring PCM TCC electrical circuit failure TCC circuit fails to provide voltage drop across solenoid Circuit open or s...

Page 2338: ... TCC The PCM picked up an excessive amount of TCC slippage during normal vehicle operation TCC slippage erratic or no torque converter clutch operation GO to Diagnosis by Symptom P1767 TCC TCC solenoid circuit failure during OBD Test TCC solenoid circuit fails to provide voltage drop across solenoid Circuit open or shorted or PCM Driver failure during OBD Test Short circuit engine stalls in second...

Page 2339: ...Resistance Continuity Test Voltage Test PARK NEUTRAL Reversing Lamp and Optional Circuits ...

Page 2340: ...onnector SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Pin Number Circuit Circuit Function 1 NOT USED 2 Signal Return 3 Torque Converter Clutch TCC Solenoid 4 Vehicle Power 5 Transmission Fluid Temperature TFT Input 6 Electronic Pressure Control EPC Solenoid 7 SSA 8 SSB 9 NOT USED 10 NOT USED ...

Page 2341: ...cuit Function 1 NOT USED 2 Signal Return Transmission Fluid Temperature TFT 3 Torque Converter Clutch TCC 4 Vehicle Power To Solenoid 5 Transmission Fluid Temperature TFT 6 Electronic Pressure Control 7 SSA 8 SSB 9 NOT USED 10 NOT USED Pin Number Circuit Circuit Function ...

Page 2342: ... Speed OSS Sensor 2 Signal Return Digital Transmission Range TR Sensor Diagnosis Chart Selector Position PID TR PID TR_D PID TR_V volts TR4 TR3A TR2 TR1 TR3A PCM Pin 64 to sigrtn PARK P N 0 0 0 0 0 0 Volts In Between REV 0 1 0 0 1 3 1 8 Volts REVERSE REV 1 1 0 0 1 3 1 8 Volts In Between REV 0 1 0 0 1 3 1 8 Volts NEUTRAL NTRL 0 1 1 0 1 3 1 8 Volts In Between O D a 1 1 1 0 1 3 1 8 Volts OVERDRIVE O ...

Page 2343: ...TR1 are all closed in PARK PARK is a good position to check for intermittent open circuits with scan tool monitoring TR_D TR4 TR3A TR2 and TR1 are all open in OVERDRIVE so OVERDRIVE is a good position to check for shorts to ground To determine the shorted components while observing TR_D unplug the TR and see if the short goes away If the short is still present unplug the transmission harness and s...

Page 2344: ...49 T94L 50 EEC V or equivalent MLP TR Cable 418 F107 007 00111 or equivalent Worldwide Diagnostic System WDS 418 F224 New Generation STAR NGS Tester 418 F052 or equivalent scan tool Transmission Tester 307 F016 007 00130 or equivalent Trans Tester TR MLP Overlay and Manual 007 00131 or equivalent 73 III Automotive Meter 105 R0057 or equivalent Gauge Transmission Solenoid Connectors 307 426 ...

Page 2345: ...hicle speed drops below this calibrated speed EC Electronically controlled HD Hydraulically disabled Shift Solenoid Failure Mode Chart Always Off Failed off due to powertrain control module and or vehicle wiring concerns shift solenoid electrically or hydraulically stuck off Solenoid Operation Chart Gear Lever Position PCM Commanded Gear Solenoids SSA SSB TCC P R N 1 ON OFF HD D 1 ON OFF HD D 2 OF...

Page 2346: ...ed Actual Gear Obtained 1 1 1 1 2 2 2 2 3 2 2 2 4 1 1 1 SSA ALWAYS ON Gear Lever Position D 2 1 PCM Gear Commanded Actual Gear Obtained 1 1 1 1 2 1 1 1 3 4 2 a 2 a 4 4 2 a 2 a SSB ALWAYS ON Gear Lever Position D 2 1 PCM Gear Commanded Actual Gear Obtained 1 4 2 a 2 a 2 3 2 a 2 a 3 3 2 a 2 a 4 4 2 a 2 a Test Step Result Action to Take NOTE Read and record all DTCs All digital TR Sensor and VSS DTCs...

Page 2347: ...elect PIDs to be monitored Select ON to turn suspect solenoid on Press SEND Wiggle all wiring and connectors to the transmission Monitor the Solenoid State for changes Select OFF to turn solenoid off Press SEND Does the suspect solenoid s fault state change PID Command PID Actual SSA SS1F SSB SS2F TCC TCCF Yes REPAIR open or short in the vehicle harness or connector No GO to A3 A3 SOLENOID FUNCTIO...

Page 2348: ...ter the following diagnostic mode on the diagnostic tool Trans Bench Mode Select Parameter SSA SSB or TCC Select ON Press SEND Turn the solenoids ON and OFF while monitoring the voltage solenoid state on the scan tool ON and OFF and listen for the solenoid to activate click Measure the voltage with the positive lead to VPWR pin and the negative lead to the TCC pin Enter the following diagnostic mo...

Page 2349: ... pins corrosion ect Using the special tool check each of the lead frame connector pins Does the special tool go through the lead frame connector pins Yes INSTALL a new lead frame GO to A8 No GO to A8 A8 CHECK SOLENOID RESISTANCE AT SOLENOID Key in OFF position Disconnect the appropriate solenoid from the lead frame Measure the solenoid resistance between the pins of the solenoid Yes GO to A9 No IN...

Page 2350: ... FOR SHORT TO GROUND Check for continuity between engine ground and appropriate solenoid pin with ohmmeter or other low current tester Connection should show infinite resistance no continuity Is there continuity Solenoid Terminal SSA SSB TCC Yes INSTALL a new solenoid No REFER to Diagnosis By Symptom in this section for diagnosis of shift or torque converter concerns ...

Page 2351: ...ng test If transmission is cold run transmission to warm it up If transmission is warm allow transmission to cool down Do the TFT PIDs increase as the transmission is warmed up or decrease as the transmission is cooled or does the TFT or TFTV drop in and out of range Yes If the TFT PIDs increase as the transmission is warmed or decrease as the transmission is cooled CLEAR all DTCs ROAD TEST to ver...

Page 2352: ...o 1 3 31 284K 100K 0 20 32 68 100K 37K 21 40 69 104 37K 16K 41 70 105 158 16K 5K 71 90 159 194 5K 2 7K 91 110 195 230 2 7K 1 5K 111 130 231 266 1 5K 0 8K 131 150 267 302 0 8K 0 54K Yes REFER to Diagnosis By Symptom in this section to diagnose an overheating concern No INSTALL a new internal harness sensor is part of harness Test Step Result Action to Take NOTE Refer to the Digital Transmission Ran...

Page 2353: ...nector This will damage the connector and result in a transmission concern Press the button and pull out on the digital TR harness connector Inspect both ends of the connector for damage or pushed out pins corrosion loose wires and missing or damaged seals Are the connector pins and harness damaged Yes REPAIR as required CLEAR DTCs and REPEAT OBD Tests No If diagnosing a DTC GO to C5 If diagnosing...

Page 2354: ... position Disconnect Powertrain Control Module PCM Inspect for damaged or pushed out pins corrosion or loose wires Disconnect Digital TR Sensor CAUTION Do not pry the connector This will damage the connector and result in a transmission concern Disconnect the digital TR sensor connector Install the EEC V Control System Breakout Box Measure the resistance between the PCM test pin 91 at the EEC V Co...

Page 2355: ... the resistance between the PCM test pin 50 at the EEC V Control System Breakout Box and TR4 circuit pin 6 at digital TR sensor connector harness side Measure the resistance between the PCM test pin 64 at the EEC V Control System Breakout Box and TR3A circuit pin 3 at digital TR sensor connector harness side Are all resistances less than 5 ohms C8 CHECK PCM HARNESS CIRCUITS FOR SHORT TO GROUND OR ...

Page 2356: ...tance between PCM test pin 34 and test pins 71 97 51 77 103 and 91 at the EEC V Control System Breakout Box and chassis ground For vehicles equipped with a 3 8L engine measure the resistance between PCM test pin 49 and test pins 71 97 51 76 77 103 and 91 at the EEC V Control System Breakout Box and chassis ground For vehicles equipped with a 4 6L engine measure the resistance between PCM test pin ...

Page 2357: ...For vehicles equipped with a 4 6L engine measure the resistance between PCM test pin 50 and test pins 71 97 51 77 103 and 91 at the EEC V Control System Breakout Box and chassis ground For vehicles equipped with a 3 8L engine measure the resistance between PCM test pin 64 and test pins 71 97 51 76 77 103 and 91 at the EEC V Control System Breakout Box and ground For vehicles equipped with a 4 6L e...

Page 2358: ...ngine measure the resistance between test pin 34 and pins 49 50 and 64 at the EEC V Control System Breakout Box For vehicles equipped with a 3 8L engine measure the resistance between test pin 49 and pins 3 50 and 64 at the EEC V Control System Breakout Box For vehicles equipped with a 4 6L engine measure the Yes INSTALL a new PCM REFER to Section 303 14 RECONNECT all components CLEAR DTCs REPEAT ...

Page 2359: ... For vehicles equipped with a 4 6L engine measure the resistance between test pin 50 and pins 34 49 and 64 at the EEC V Control System Breakout Box For vehicles equipped with a 3 8L engine measure the resistance between test pin 64 and pins 3 49 and 50 at the EEC V Control System Breakout Box For vehicles equipped with a 4 6L engine measure the resistance between test pin 64 and pins 34 49 and 50 ...

Page 2360: ...illustration preceding these pinpoint tests NOTE Read and record all DTCs All digital TR Sensor and VSS DTCs must be repaired before entering Output State Control OSC D1 ELECTRONIC DIAGNOSTICS Key in OFF position Select PARK Check to make sure the transmission harness connector is fully seated pins are fully engaged in the connector and in good condition before proceeding Connect the diagnostic to...

Page 2361: ...PWR solenoid pin and negative lead to a good ground Is voltage greater than 10 volts Yes GO to D4 No REPAIR the circuit CLEAR the DTCs REPEAT the OBD Tests D4 ELECTRICAL SIGNAL CHECK Measure the voltage with positive lead connected to VPWR solenoid pin and connect negative lead to the signal pin of the EPC solenoid Turn the solenoids ON and OFF while monitoring the voltage reading solenoid state o...

Page 2362: ...n Harness Measure the resistance between the pins of the solenoid Measure the resistance of the EPC solenoid Is the resistance between 2 48 and 5 66 ohms Yes GO to D7 No INSTALL a new solenoid CLEAR the DTCs REPEAT the OBD Tests D7 CHECK SOLENOID FOR SHORT TO GROUND Check for continuity between engine GROUND and the EPC solenoid terminals with ohmmeter or other low current tester less than 200 mil...

Page 2363: ...s Diagnosis PC ED manual for diagnosis of PCM E2 DRIVE CYCLE TEST While monitoring the OSS Speed PID drive the vehicle so that the transmission upshifts and downshifts through all gears Does the OSS Speed PID increase and decrease with engine and vehicle speed Yes CLEAR all DTCs ROAD TEST to verify if concern is still present If concern is still present REFER to Diagnosis By Symptom in this sectio...

Page 2364: ...Test No INSTALL a new solenoid and or body REFER to the Diagnostic Trouble Code Charts in this section for code description GO to F2 F2 TRANSMISSION DRIVE CYCLE TEST Carry out transmission drive cycle test Carry out On Board Diagnostic Test Does the vehicle upshift and downshift OK Yes GO to F3 No REFER to Diagnosis By Symptom in this section to diagnose shift concerns F3 RETRIEVE DTCS Connect the...

Page 2365: ......

Page 2366: ...g out the stall speed test If the line pressure is low at stall do not carry out stall speed test or further transmission damage will occur Do not maintain WOT in any transmission range for more than five seconds This test verifies that the line pressure is within specification 1 Connect pressure gauge to line pressure tap SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manua...

Page 2367: ...ap a Line Pressure Tap Forward Clutch Tap Intermediate Clutch Tap Direct Clutch Tap M1 172 241 kPa 25 35 psi 517 655 kPa 75 95 psi 448 586 kPa 65 85 psi 0 34 kPa 0 5 psi 0 34 kPa 0 5 psi M2 103 241 kPa 15 25 psi 413 551 kPa 60 80 psi 344 482 kPa 50 70 psi 393 517 kPa 55 75 psi 0 34 kPa 0 5 psi 1 172 241 kPa 25 35 psi 517 655 kPa 75 95 psi 448 586 kPa 65 85 psi 0 34 kPa 0 5 psi 0 34 kPa 0 5 psi 2 1...

Page 2368: ...kPa 60 79 psi 344 482 kPa 50 70 psi 379 517 kPa 55 75 psi 0 34 kPa 0 5 psi 3 172 241 kPa 25 35 psi 517 655 kPa 75 95 psi 372 579 kPa 54 84 psi 482 613 kPa 70 89 psi 379 586 kPa 55 85 psi 4 241 310 kPa 35 45 psi 620 758 kPa 90 110 psi 0 34 kPa 0 5 psi 586 730 kPa 85 105 psi 551 689 kPa 80 100 psi Line Pressure Diagnosis Chart Test Results Possible Source High At Idle In All Positions Wiring Harness...

Page 2369: ...ing brake firmly for each stall speed test 1 Find the specified stall rpm for the vehicle see the stall speed diagnosis chart Use a grease pencil to mark the rpm on the dial of a tachometer 2 Connect a tachometer to the engine 3 NOTE If the rpm recorded by the tachometer exceeds the maximum limits release the accelerator pedal immediately because clutch or band slippage is indicated In each of the...

Page 2370: ...actions Air Pressure Tests Transmission Air Test Plate Stall Speed Diagnosis Chart Selector Position Stall Speeds High Stall Speeds Low D Planetary One Way Clutch D 2 and 1 Forward Clutch or Intermediate Clutch D 2 1 and R Carry Out Pressure Test Torque Converter Stator One Way Clutch or Engine Driveability Concerns R Reverse Clutch or Low Reverse Band or Servo Item Part Number Description 1 Conve...

Page 2371: ...ble clean and inspect them to locate the source of the concern If air pressure applied to the clutch passages fails to operate a clutch or operates clutches simultaneously inspect the fluid passages in the case If air pressure applied to the accumulator fails to operate an accumulator remove and inspect case passages and piston Clutch Pressure Test The Clutch Pressure Test will diagnose a low pres...

Page 2372: ...a leak in the corresponding clutch pressure circuit The gauges on the line pressure tap and clutch pressure tap can be switched to confirm that gauge calibration differences are not the cause Carry out the appropriate procedure to correct the clutch leak problem ...

Page 2373: ...s install a new cooler line fitting and tighten to specification The same procedure should be followed for fluid leaks between the radiator cooler and the cooler line fittings in this section refer to Section 307 02 Check the engine coolant in the radiator If transmission fluid is present in the coolant the cooler in the radiator is probably leaking The cooler can be further checked for leaks by d...

Page 2374: ...ensor seal 11 7H103 Output shaft speed OSS sensor 12 7B498 Manual control lever seal assembly 13 7086 Extension housing gasket 14 7A039 Extension housing 15 N803737 S1101 Bolt M8 1 25 x 30 15 N606047 S101 Bolt M8 1 25 x 70 15 N803521 S1101 Bolt M8 1 25 x 1 25 x 0 54 15 N811524 S101 Bolt M8 1 25 x 42 16 7052 Oil seal 17 7Z276 Seal bulkhead assembly 18 7G276 Bulkhead assembly wiring connector 19 7G2...

Page 2375: ...e torque converter housing only near the outside diameter of the housing 2 Fluid leakage by the outside diameter of the front pump seal and front pump body will follow the same path that leaks by the inside diameter of the front pump seal follow 3 Fluid that leaks by a front pump to case bolt or pump gasket will be deposited on the inside of the torque converter housing only Fluid will not be depo...

Page 2376: ...ent and blow dry with compressed air 3 Wash out the torque converter housing the front of the flexplate and the converter drain plugs The torque converter housing may be washed out using cleaning solvent and a squirt type oil can Blow all washed areas dry with compressed air 4 Start and run the engine until the transmission reaches its normal operating temperature Observe the back of the cylinder ...

Page 2377: ......

Page 2378: ...vel indicator from fluid filler tube 2 Place funnel in fluid filler tube 3 Position the vehicle on a hoist For additional information refer to Section 100 02 4 Remove the cooler return line top fitting from the fitting on the transmission case 5 Connect one end of a hose to the cooler return line and route other end of the hose up to a point where it can be inserted into the funnel at the fluid fi...

Page 2379: ......

Page 2380: ... Plate Transmission 307 246 T92P 7006 A Breakout Box EEC V Control System 418 049 T94L 50 EEC V or equivalent MLP TR Cable 418 F107 007 00111 or equivalent Worldwide Diagnostic System WDS 418 F224 New Generation STAR NGS Tester 418 F052 or equivalent scan tool Transmission Tester 307 F016 007 00130 or equivalent Trans Tester TR MLP Overlay and Manual 007 00131 or equivalent 73 III Automotive Meter...

Page 2381: ...ications of condition c checking the fluid levels d carrying out other test procedures as directed 4 NOTE Not all concerns and conditions with electrical components will set a diagnostic trouble code DTC Be aware that the components listed may still be the cause Verify correct function of these components prior to proceeding to the Hydraulic Mechanical Routine listed Begin with the Electrical Rout...

Page 2382: ...peration 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 Overheatin...

Page 2383: ...equired Bolts not tightened to specifications Tighten bolts to specifications Gaskets damaged Inspect gaskets for damage and install a new gasket 2 3 accumulator and seals damaged Inspect piston seals and bore for damage Repair as required Pressure regulator valve Inspect the diameter for wear Pump Assembly Bolts not tightened to specifications Tighten bolts to specifications Porosity cross leaks ...

Page 2384: ...essure Chart for specifications If pressures are low check the following components oil filter and seal assembly main controls reverse servo pump assembly reverse clutch assembly Fluid Filter and Seal Assembly Plugged damaged Install a new filter and seal assembly Main Controls No 6 shuttle ball manual valve main regulator valve 1 2 accumulator seals stuck or damaged Inspect for damage Repair as r...

Page 2385: ...ndition 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 corr...

Page 2386: ...equired 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 o...

Page 2387: ... 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 ...

Page 2388: ...l a new gasket Case 1 2 accumulator seals stuck or damaged Inspect for damage Repair as required Low Reverse Servo Seals piston and cover damaged Inspect for damage Repair as required Servo cover retaining ring assembled incorrectly Pump Assembly Bolts not tightened to specification Tighten bolts to specification Porosity cross leaks ball missing or leaking Inspect pump assembly Install new as req...

Page 2389: ...assembly main controls and pump assembly Fluid Filter and Seal Assembly Plugged damaged Install a new filter and seal assembly Filter seal damaged Main Controls 3 4 shift valve main regulator valve stuck or damaged Inspect and repair as required Bolts not tightened to specifications Tighten bolts to specifications Gaskets damaged Inspect for damage and repair as required Case 2 3 or 1 2 accumulato...

Page 2390: ... 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 output...

Page 2391: ...TRICAL 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 an...

Page 2392: ...rrect 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 Ro...

Page 2393: ... 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 Pos...

Page 2394: ...ids 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 or Go To Pinpoint Test C Repair as required Clear DTCs road test and repeat Self Test 316 HYDRAULIC MECHANICAL ROUTINE Shift Linkage Cable Digital TR Sensor Damaged or incorrectly adjusted Inspect and repair as r...

Page 2395: ...trol System Go To Pinpoint Test A or Go To Pinpoint Test C Repair as required Clear DTCs road test and repeat Self Test 317 HYDRAULIC MECHANICAL ROUTINE Shift Linkage Cable 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...

Page 2396: ...quired 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...

Page 2397: ...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 bol...

Page 2398: ... Go To Pinpoint Test E Repair as required Clear DTCs road test and repeat Self Test Engine driveability concerns Refer to Routine 253 322 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 transmissi...

Page 2399: ...n elements worn or damaged Inspect for damage Repair as required Check ball stuck damaged or not seating correctly Inspect for damage Repair as required Input Shaft Seals damaged Inspect for damage Repair as required Shift Concerns 4 3 Shift Automatic Possible Component Reference Action 223 ELECTRICAL ROUTINE Powertrain Control System Electrical inputs outputs vehicle wiring harnesses PCM shift so...

Page 2400: ...r as required Intermediate one way clutch assembly damaged Inspect for damage Repair as required Forward Clutch Assembly Seals or piston damaged Inspect for damage Repair as required Friction elements damaged worn Inspect for damage Repair as required Check ball stuck damaged or not seating correctly Inspect for damage Repair as required Forward clutch piston and return spring damaged Inspect for ...

Page 2401: ...erns 2 1 Shift Automatic Possible Component Reference Action 225 ELECTRICAL ROUTINE Powertrain Control System Electrical inputs outputs vehicle wiring harnesses PCM shift solenoids 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 Repair as required Clear DTCs road test and repeat Se...

Page 2402: ... the Powertrain Control System Go To Pinpoint Test B or Go To Pinpoint Test E Repair as required Clear codes road test and repeat Self Test 340 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 cab...

Page 2403: ...Refer to the Powertrain Control Emissions Diagnosis PC ED manual for diagnosis and testing of the Powertrain Control System Go To Pinpoint Test B or Go To Pinpoint Test A Repair as required Clear DTCs road test and repeat Self Test 341 HYDRAULIC MECHANICAL ROUTINE Main Control Drain back valve torque converter clutch TCC and plunger stuck damaged or assembled incorrectly Inspect for damage Repair ...

Page 2404: ...e Test Carry out Transmission Self Test If condition still exists continue diagnostics Main Controls Solenoid pressure regulator valve No 7 check ball bypass clutch control valve and plunger converter pressure limit valve stuck damaged or assembled incorrectly Inspect for damage Repair as required Bolts not tightened to specifications Tighten bolts to specifications Solenoid screen blocked or dama...

Page 2405: ...air as required Overdrive Reverse band manual 1st only damaged Inspect for damage Repair as required OD band reverse clutch drum assembly worn or damaged manual 2nd only Inspect for damage Repair as required Reverse Band Manual 1st Only Damaged or incorrectly adjusted Inspect for damage Repair as required Other Concerns Shift Lever Efforts High Possible Component Reference Action 251 ELECTRICAL RO...

Page 2406: ...orm fluid leakage check Repair as required Other Cooler fitting cooler lines pressure tap converter drain plug band anchor pins Locate the source of the leak Repair as required Other Concerns Poor Vehicle Performance Possible Component Reference Action 253 ELECTRICAL ROUTINE Powertrain Control System Electrical inputs outputs vehicle wiring harnesses shift solenoids digital TR sensor torque conver...

Page 2407: ...rence Action 254 ELECTRICAL ROUTINE No Electrical Concerns 354 HYDRAULIC MECHANICAL ROUTINE For Noises Vibrations That Change With Engine Speed Converter components balance weight Locate source of disturbance Repair as required Fluid level low pump cavitation Pump assembly Engine drive accessories Cooler lines grounding out Flexplate For Noises Vibrations That Change With Vehicle Speed Engine moun...

Page 2408: ... engine starting system hardware 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 C Repair and adjust as required 355 HYDRAULIC MECHANICAL ROUTINE Shift Linkage Digital TR Sensor Damaged or incorrectly adjusted Inspect and repair as required Verify transmission shift...

Page 2409: ...ect assembly and repair as required Other Concerns Overheating Possible Component Reference Action 257 ELECTRICAL ROUTINE Refer to Routine 240 340 Torque Converter Operation Concern No Apply 357 HYDRAULIC MECHANICAL ROUTINE Fluid Incorrect level Adjust fluid to correct level Condition Inspect condition of fluid Other Damaged blocked or reversed cooler lines or restriction in the transmission oil c...

Page 2410: ......

Page 2411: ...end of the steel transmission cooler lines as described below Connect the cleaner tank pressure line to the steel transmission cooler return line longest line Connect a tank return hose to the steel transmission cooler pressure line shorter line Place the outlet end of this hose in the solvent tank reservoir 3 Turn on solvent pump and allow the solvent to circulate a minimum of 5 minutes cycling s...

Page 2412: ...onverter drain plug Vehicles without a torque converter drain plug Use the method that is applicable to your vehicle All vehicles using a suitable flush and fill machine 1 With the vehicle in NEUTRAL position on a hoist For additional information refer to Section 100 02 2 Use a suitable flush and fill machine to change the fluid 3 When connecting the flush and fill machine connect the machine to t...

Page 2413: ... 24 liter 0 5 pint until the correct level is achieved fluid should be in the cross hatched area of the fluid level indicator Draining Vehicles equipped with a torque converter drain plug 1 With the vehicle in NEUTRAL position on a hoist For additional information refer to Section 100 02 2 Loosen the transmission fluid pan bolts and allow the fluid to drain 3 After the fluid has drained remove the...

Page 2414: ... transmission fluid pan transmission fluid pan gasket and magnet 8 Thoroughly flush the cooler tubes For additional information refer to Transmission Fluid Cooler Backflushing and Cleaning in this section Refill 9 After the torque converter has drained install a new drain plug ...

Page 2415: ...2 Install the bolts 13 CAUTION The use of any other transmission fluid can result in the transmission failing to operate in a normal manner or transmission failure Fill the transmission Add 4 7 liters 5 qts of clean automatic transmission fluid to the transmission through the fluid filler tube 14 Start the engine Move the transmission range selector lever through all the gear ranges checking for e...

Page 2416: ...on a hoist For additional information refer to Section 100 02 2 Loosen the transmission fluid pan bolts and allow the fluid to drain 3 After the fluid has drained remove the transmission fluid pan 4 Do not remove the fluid filter It is not necessary to change the fluid filter during a normal maintenance fluid change 5 Clean and inspect the transmission fluid pan transmission fluid pan gasket and m...

Page 2417: ...smission failure Fill the transmission Add 4 7 liters 5 qts of clean automatic transmission fluid to the transmission through the fluid filler tube 10 Start the engine Move the transmission range selector lever through all the gear ranges checking for engagements 11 With the engine running and the transmission at normal operating temperature 66 77 C 150 170 F check and adjust the transmission flui...

Page 2418: ......

Page 2419: ...ts to fail this will effect the operation of the transmission CAUTION Use of a fluid other than specified could result in transmission failure Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for the transmission code 3 When filling a dry transmission and torque converter refer to General Specifications chart in this section for capacity Check th...

Page 2420: ...ssion fluid pan gasket 6 Pull down evenly and remove the transmission fluid filter and seal 7 Remove torque converter housing plug 8 Remove the torque converter drain plug and drain the torque converter Rotate the crankshaft to access the drain plug ...

Page 2421: ...he fluid cooler tubes For additional information refer to Transmission Fluid Cooler Backflushing and Cleaning in this section Installation 1 NOTE A new torque converter drain plug must be used Install the torque converter drain plug 2 Install the torque converter housing plug ...

Page 2422: ...se a new filter and seal The filter may be reused if no excessive contamination is present Install a new fluid filter and seal as required 4 Position the pan magnet into the transmission fluid pan 5 NOTE The transmission fluid pan gasket is reusable Clean and inspect for damage if not damaged the gasket should be reused Install the transmission fluid pan and gasket 1 Position the transmission flui...

Page 2423: ...e strategy The vehicle may need to be driven 16 km 10 miles or more to relearn the strategy Connect the battery ground cable For additional information refer to Section 414 01 8 NOTE When filling a dry transmission and converter start with a minimum of 4 7 liters 5 quarts Fill the transmission to the correct level with clean automatic transmission fluid ...

Page 2424: ...IR Transmission Filler Tube Removal 1 Remove the bolt 2 Remove the fluid filler tube Installation 1 To install reverse the removal procedure SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual ...

Page 2425: ......

Page 2426: ...connect the solenoids Disconnect the molded lead frame from the solenoids Disconnect the molded lead frame from the solenoids 1 Disconnect the shift solenoid SSA and SSB 2 Disconnect the torque converter clutch TCC 3 Disconnect the electronic pressure control EPC solenoid 4 Disconnect the bulkhead inter connector 3 Remove the manual control valve detent lever spring 1 Remove the bolt SECTION 307 0...

Page 2427: ...ve body and discard the pump outlet screen Installation 1 NOTE Make sure that the drive pin of the manual valve detent lever assembly engages the manual valve in the correct location prior to installing the bolts Position the main control valve body gasket and main control valve body using the two alignment bolts as a guide ...

Page 2428: ...2 NOTE The main control valve body bolts will be tightened in later steps Loosely install the bolts 3 NOTE The main control valve body bolts will be tightened in later steps Loosely install the bolts ...

Page 2429: ...4 Install the manual control valve detent lever spring 1 Position the manual control valve detent lever spring 2 Install the bolt 5 Tighten the main control valve body bolts in the sequence shown ...

Page 2430: ...nnector by pressing it in place by hand and fully seating the connector in place Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place Make sure that the terminals pass fully through the connector slots Connect the TCC by pressing it in place by hand and fully seating the connector in place Make sure that the terminals pass fully through the connector sl...

Page 2431: ...8 Install the transmission filter and pan For additional information refer to Fluid Pan Gasket and Filter in this section ...

Page 2432: ......

Page 2433: ...haft are a balanced assembly Mark the driveshaft flange and the rear companion flange for correct alignment during assembly 3 Remove the four driveshaft bolts SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Special Tool s Slide Hammer 100 001 T50T 100 A Installer Transmission Extension Housing Fluid Seal 308 002 T61L 7657 A Remover Transmission Fluid Seal 307 048 T74P ...

Page 2434: ...the transmission 5 Use a high lift transmission jack to support the transmission 6 Remove the transmission crossmember bolts 7 Remove the transmission mount and crossmember 8 Using the special tools remove the extension housing seal ...

Page 2435: ...ing and gasket 1 Remove the bolts and the nuts 2 Remove the extension housing and gasket Installation 1 Install the extension housing and gasket 1 Install the extension housing gasket and housing 2 Install the bolts and the nuts 2 Using the special tool install the new extension housing seal ...

Page 2436: ...crossmember 5 Install the transmission crossmember bolts 6 Remove high lift transmission jack 7 NOTE The output shaft and the driveshaft are a balanced assembly Install the driveshaft Align the yellow dots and position the driveshaft on the transmission Install the driveshaft ...

Page 2437: ...t balance align the marks made during disassembly for the rear axle flange and the driveshaft yoke Install the four bolts 9 Install the filter and pan For additional information refer to Fluid Pan Gasket and Filter in this section ...

Page 2438: ...sconnect the solenoids Disconnect the molded lead frame from the solenoids Disconnect the molded lead frame from the solenoids 1 Disconnect the shift solenoid SSA and SSB 2 Disconnect the torque converter clutch TCC 3 Disconnect the electronic pressure control EPC solenoid 4 Disconnect the bulkhead inter connector 3 Remove the EPC solenoid 1 Remove the bolt and EPC solenoid bracket SECTION 307 01 ...

Page 2439: ...asses through any lead frame connector pins or does not feel like it makes a good contact install a new lead frame 3 Connect the molded lead frame to the solenoids Connect the bulkhead inter connector by pressing it in place by hand and fully seating the connector in place Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place Make sure that the terminals...

Page 2440: ...t solenoid SSA and SSB by pressing it in place by hand and fully seating the connector in place Make sure that the terminals pass fully through the connector slots 4 Install the manual control lever For additional information refer to Manual Control Lever Shaft and Seal in this section ...

Page 2441: ...Gasket and Filter in this section 2 Disconnect the digital transmission range TR sensor electrical connector 3 Disconnect the transmission shift linkage 4 Remove the digital TR sensor SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Special Tool s Installer Shift Shaft Fluid Seal 307 050 T74P 77498 A Alignment Gauge TR Sensor 307 351 T97L 70010 A ...

Page 2442: ...lve detent lever spring 1 Remove the bolt 2 Remove the manual control valve detent lever spring 6 NOTE Use a shop cloth to protect the transmission case surface Remove the manual lever shaft retaining pin 7 Remove the nut and slide the manual control lever shaft out of the case ...

Page 2443: ...ever 2 Remove the parking lever actuating rod 9 CAUTION Use care not to damage the manual control lever shaft bore New seal may leak due to damage to the bore Remove the manual control lever shaft seal Installation 1 Using the special tool install the manual control lever seal ...

Page 2444: ...ll the manual valve detent lever 3 Install the manual control lever shaft 1 Install the manual control lever shaft 2 Install the nut 3 Install the manual lever shaft retaining pin 4 Install the manual valve detent lever spring 1 Position the manual valve detent lever spring 2 Install the bolt ...

Page 2445: ...nstall the digital TR sensor 2 Loosely install the bolts 6 NOTE The tool is designed to fit snug NOTE Manual shift lever shaft must be in the neutral position Using the special tools align the digital TR sensor slots 7 Tighten the bolts ...

Page 2446: ... overdrive connect the shift control cable 9 Install the digital TR sensor electrical connector 10 Install the filter and transmission fluid pan For additional information refer to Fluid Pan Gasket and Filter in this section ...

Page 2447: ... 01 2 Raise and support the vehicle For additional information refer to Section 100 02 3 Disconnect the connector 4 Disconnect the manual lever shift control cable 5 Remove the digital TR bolts and the TR sensor SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Special Tool s Alignment Gauge TR Sensor 307 351 T97L 70010 A ...

Page 2448: ...digital TR sensor and loosely install the bolts 2 NOTE The tool is designed to fit snugly NOTE Manual shift lever shaft must be in the neutral position Using the special tool align the digital TR sensor slots 3 Tighten the bolts ...

Page 2449: ...sor electrical connector 6 Lower the vehicle 7 NOTE When the battery is disconnected and reconnected some abnormal driving symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km 10 miles or more to relearn the strategy Connect the battery ground cable ...

Page 2450: ......

Page 2451: ...ng 2 Remove the reverse band servo retaining ring 3 Remove the reverse servo assembly 1 Remove the reverse band servo cover 2 Remove the reverse band servo piston and rod 3 Remove the reverse band servo spring SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Special Tool s Dial Indicator Gauge with Holding Fixture 100 002 TOOL 4201 C Remover Installer Servo Piston 307 2...

Page 2452: ...to facilitate assembly and prevent damage to the seal Install the reverse servo return spring and piston Do not install the piston cover 2 Install the special tool and tighten the band apply bolt 3 Attach the special tool to the transmission Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator ...

Page 2453: ...vel on the dial indicator is within specification 6 If piston travel is not within specification select and install the correct servo piston assembly to bring the servo piston travel within specification 1 One groove 2 Two groove 3 Three groove 7 Remove the dial indicator and servo selection tool ...

Page 2454: ...ervo piston and rod 3 Install the reverse band servo cover 9 Using the special tool install the reverse servo retaining ring 1 Compress the servo spring 2 Install the reverse band servo retaining ring 10 Install the main control valve body For additional information refer to Main Control Valve Body in this section ...

Page 2455: ......

Page 2456: ...Case bore damage may result from trying to pry on overdrive servo internal retaining ring Using the special tool compress the servo spring to remove the overdrive servo retaining ring 3 Remove the overdrive servo piston and return spring Installation 1 Install the overdrive servo piston assembly 1 Install the overdrive servo piston return spring SECTION 307 01 Automatic Transaxle Transmission 2003...

Page 2457: ...rdrive servo piston assembly 2 Use the special tool to install the overdrive servo piston retaining ring 3 Install the main control valve body For additional information refer to Main Control Valve Body in this section ...

Page 2458: ...mulator 1 Remove the 1 2 accumulator cover 2 Remove the lower 1 2 accumulator spring 3 Remove the accumulator piston 4 Remove the upper 1 2 accumulator spring Installation 1 Install the 1 2 accumulator 1 Install the 1 2 accumulator upper spring 2 Install the accumulator piston 3 Install the 1 2 accumulator lower spring 4 Install the cover and seal assembly SECTION 307 01 Automatic Transaxle Transm...

Page 2459: ...2 Compress the accumulator and install the accumulator piston retaining ring ...

Page 2460: ...this section 2 Remove the 2 3 accumulator piston retainer 3 Remove the accumulator piston and spring Installation 1 Install the 2 3 accumulator assembly 1 Install the accumulator piston 2 Install the accumulator piston spring 3 Install the accumulator spring retainer SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual ...

Page 2461: ...2 Install the main control valve body For additional information refer to Main Control Valve Body in this section ...

Page 2462: ...ssion with a suitable transmission jack 3 Remove the crossmember 1 Disconnect the HO2S sensors and position them aside 2 Remove the bolts from the crossmember to the extension housing 3 Remove the bolts from the crossmember to the body and remove the crossmember 4 To install reverse the removal procedure SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual ...

Page 2463: ......

Page 2464: ... a major cause for recurring transmission concerns and must be removed from the system before the transmission is returned to use The cleaning of foreign material from the direct clutch check ball is often omitted This omission can lead to repeat repair of the transmission If equipped a new oil to air cooler must be installed under the following conditions for installation refer to Section 307 02 ...

Page 2465: ...luid 7 NOTE To maintain the initial driveshaft balance mark the REAR driveshaft yoke and the axle pinion flange so they may be installed in their original positions Remove the driveshaft bolts 8 Separate the driveshaft from the transmission 9 Disconnect the connector ...

Page 2466: ...10 Disconnect the connector 11 Remove the cover 12 Remove the four nuts 13 Remove the starter 1 Disconnect the electrical connectors 2 Remove the bolts 3 Remove the starter ...

Page 2467: ...isconnect the transmission shift linkage 15 Remove the cable from the bracket 16 Disconnect the transmission fluid cooler tubes 17 Position the high lift jack under the transmission 18 Unclip the connectors ...

Page 2468: ...19 Remove the bolts 20 Remove the bolts 21 Remove the bolts 22 Remove the bolt 23 Remove the bolts ...

Page 2469: ...on Secure the torque converter in the transmission Using the special tool secure the torque converter in the transmission then lower the transmission from the vehicle 26 Carry out the transmission fluid cooler backflushing and cleaning For additional information refer to Transmission Fluid Cooler Backflushing and Cleaning ...

Page 2470: ......

Page 2471: ...0 001 T50T 100 A Holding Fixture Transmission 307 003 T57L 500 B Slide Hammer 307 005 T59L 100 B Remover Transmission Fluid Seal 307 048 T74P 77248 A Handle Torque Converter 307 091 T81P 7902 C Remover Transmission Fluid Pump 307 221 T89T 70010 A Remover Installer Servo Piston 307 251 T92P 70023 A Remover Torque Converter Fluid Seal ...

Page 2472: ...tool 2 Using the special tools remove torque converter 3 Using the special tool mount the transmission to the bench 307 309 T94P 77001 BH Retainer Torque Converter 307 346 T97T 7902 A Remover Bearing Cup 308 047 T77F 1102 A ...

Page 2473: ...ket 5 Clean the transmission fluid pan and pan magnet 6 CAUTION If installing a new filter and grommet remains in the main control bore carefully use a small screwdriver to remove the grommet Use care not to damage the main control bore NOTE If transmission is being repaired for a contamination related failure use a new filter and seal The filter may be reused if no excessive contamination is pres...

Page 2474: ... the molded lead frame from the solenoids Disconnect the molded lead frame from the solenoids 1 Disconnect the shift solenoid SSA and SSB 2 Disconnect the torque converter clutch TCC 3 Disconnect the electronic pressure control EPC solenoid 4 Disconnect the bulkhead inter connector 8 Remove the output shaft speed OSS sensor 1 Remove the bolt 2 Remove the OSS sensor ...

Page 2475: ...ove the digital TR sensor 10 Remove the manual control valve detent lever spring 1 Remove the bolt 2 Remove the manual control valve detent lever spring 11 Remove the 24 main control valve body bolts and the main control valve body 12 Remove and discard the pump outlet screen ...

Page 2476: ...he manual lever shaft retaining pin 14 Remove the manual lever shaft inner nut Slide the manual control lever shaft out of the case while removing the inner nut 15 Remove the parking lever actuating rod 1 Remove the manual valve detent 2 Remove the parking lever actuating rod ...

Page 2477: ...al may leak Remove the manual control lever shaft seal 17 Remove the EPC solenoid 1 Remove the bolt and EPC solenoid bracket 2 Remove the EPC solenoid 18 Remove the 2 3 accumulator spring retainer 19 Remove the 2 3 accumulator piston 1 Remove the 2 3 accumulator spring 2 Remove the 2 3 accumulator piston ...

Page 2478: ... band servo piston and rod 3 Remove the reverse band servo spring 22 NOTE If tool is not available extreme care must be taken Spring pressure will force overdrive servo piston assembly out of case Case bore damage may result from trying to pry on internal retaining ring Using the special tool compress the piston spring then remove the overdrive servo piston retainer ...

Page 2479: ...ve servo piston return spring 24 Compress the 1 2 accumulator cover and remove the retaining ring 25 Remove the 1 2 accumulator upper spring 1 Remove the 1 2 accumulator spring cover 2 Remove the 1 2 accumulator lower spring 3 Remove the 1 2 accumulator 4 Remove the 1 2 accumulator upper spring ...

Page 2480: ... extension housing gasket 28 Remove the parking pawl 1 Remove the parking pawl shaft 2 Remove the parking pawl return spring 3 Remove the parking pawl 29 Rotate the transmission to the vertical position with the output shaft towards the floor 30 CAUTION Extreme care must be taken during transmission connector removal Do not use a hammer on the connector body Place a screwdriver on the flat portion...

Page 2481: ...the front pump seal 32 NOTE These bolts have been coated with sealant High break torque may be required to remove the bolts Remove the bolts 33 Using the special tools remove the front pump support 34 Remove and discard the pump gasket ...

Page 2482: ...verdrive band friction material by the reverse clutch drive lugs Remove the following components as an assembly Intermediate clutch pack Intermediate one way clutch Reverse clutch Forward clutch assembly 37 Disengage and remove the overdrive band 38 Remove the forward clutch hub and the No 3 forward clutch hub front bearing ...

Page 2483: ... Align the reverse sun shell with the overdrive band anchor pin for removal 41 Remove the following components as an assembly Forward clutch sun gear No 5 forward clutch sun gear bearing Reverse clutch sun gear No 4 forward clutch hub bearing ...

Page 2484: ...pport retaining ring and note location for assembly 43 Remove the case to planet support spring 44 Remove the planetary gear support and planetary as an assembly 45 Remove the reverse clutch band 46 Remove the retaining ring ...

Page 2485: ...47 Remove the direct clutch pack 48 Remove the No 8 bearing 49 Remove the output shaft output shaft ring gear assembly and direct clutch 50 Remove the No 9 case rear bearing ...

Page 2486: ...51 Inspect and if necessary use the special tools to remove the rear case bushing ...

Page 2487: ...CTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Item Part Number Description 1 Valve plug retainer part of 7A100 2 Main pressure booster valve sleeve part of 7A100 3 Main pressure booster valve part of 7A100 4 Main pressure regulator valve spring part of 7A100 5 Main regulator valve part of 7A100 ...

Page 2488: ... Valve plug retainer part of 7A100 24 2 3 backout valve part of 7A100 25 2 3 backout valve spring part of 7A100 26 Spring retaining plate part of 7A100 27 Spring retaining plate part of 7A100 28 Pressure regulator valve spring part of 7A100 29 Pressure regulator valve part of 7A100 30 Control manual valve part of 7A100 31 Retaining ring part of 7A100 32 Solenoid screen 33 1 2 shift valve part of 7...

Page 2489: ...e the TCC solenoid 2 Remove the two reinforcement plates 1 Remove the bolts 2 Remove the plates 3 Remove the separator plate and discard the gaskets 4 NOTE Note the location of the eight coasting booster valve shuttle balls for assembly Remove the eight coasting booster valve shuttle balls 45 Control valve plate part of 7A100 ...

Page 2490: ...5 Remove the converter drain back valve and solenoid pressure supply screen 6 Remove the main control valve body cover plate 1 Remove the 13 bolts 2 Remove the valve body cover plate and gasket ...

Page 2491: ...lean transmission fluid It is also good practice to lubricate the subassemblies as they are installed in the case Needle bearings thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly Many components and surfaces in the transmission are precision machined Careful handling during disassembly cleaning inspection and assembly can pr...

Page 2492: ...3 Install the eight coasting booster valve shuttle balls 4 Install the converter drain back valve and solenoid pressure supply screen ...

Page 2493: ...6 Install the two reinforcement plates 1 Position the plates 2 Install the bolts 7 NOTE Inspect the shift solenoid O rings and TCC solenoid O rings for damage Install the shift solenoid 1 Position the TCC solenoid 2 Position the shift solenoid ...

Page 2494: ...3 Install the bolt ...

Page 2495: ...nt Pump Fluid Seal 307 014 T63L 77837 A Protector Piston Seal 307 339 T95L 77005 A Item Part Number Description 1 7902 Torque converter 2 7A248 Front pump O ring 3 N605789 S101 Bolt 4 Pump body assembly 5 N605787 S1000 Front pump support bolt 6 7D014 No 1 pump support thrust washer 7 7D020 Reverse clutch cylinder seal 8 7D019 Forward clutch cylinder seal 9 7E005 Intermediate clutch piston 10 7F224...

Page 2496: ...rt 1 Remove the bolts 2 Remove the front pump support 3 Remove the seal rings 11 7F225 Intermediate clutch piston inner seal 12 7A108 Pump support 13 Pump outer gerotor gear 14 Pump inner gerotor gear 15 7A136 Pump gasket 16 Pump bushing 17 7A248 Pump inner seal 18 391855 S100 Converter drain plug ...

Page 2497: ...g retainer tabs and remove the spring retainer assembly 6 Remove the intermediate clutch piston 7 Remove the clutch piston seals 1 Remove the intermediate clutch piston outer seal 2 Remove the intermediate clutch piston inner seal 8 Remove and discard the front pump seal ...

Page 2498: ... clutch piston seals 1 Install the intermediate clutch piston outer seal 2 Install the intermediate clutch piston inner seal 3 NOTE Coat the intermediate clutch piston outer seal inner seal and pump body with petroleum jelly Install the intermediate clutch piston into the special tool ...

Page 2499: ...ttom of the pump body bore exerting even pressure and remove the special tool 5 CAUTION The piston bleed hole must be located at 12 o clock position towards the top of the transmission Shift problems may occur if installed incorrectly NOTE The piston bleed hole is the only round hole in the pump body Locate the piston bleed hole 6 Install by snapping the spring retainer assembly on pump body ...

Page 2500: ...s that must face the pump body or damage will result Install the inner and outer fluid pump gerotor gears 8 NOTE The reverse clutch cylinder seal rings are larger than the forward clutch cylinder seals Install the seal rings 9 Install a new front pump seal ...

Page 2501: ...10 Assemble the front pump 1 Position the pump support to the pump body assembly 2 Install the bolts ...

Page 2502: ...snap ring 2 Remove the intermediate one way clutch Assembly 1 NOTE The intermediate one way clutch must rotate counterclockwise when installed on the reverse clutch drum and will make a ratchet sound Install the intermediate one way clutch 1 Install the intermediate one way clutch 2 Install the snap ring SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Item Part Number ...

Page 2503: ......

Page 2504: ...Tool s Dial Indicator Gauge with Holding Fixture 100 002 TOOL 4201 C Compressor Clutch Spring 307 015 T65L 77515 A Protector Transmission Reverse Clutch Outer Fluid Seal 307 424 Protector Transmission Reverse Clutch Inner Fluid Seal 307 425 Compressor Clutch Spring 307 086 T80L 77405 A Material Item Specification MERCON V Automatic Transmission Fluid XT 5 QM XT 5 DM MERCON V ...

Page 2505: ... bearing surfaces Install new parts if they are deeply scored or burred 5 Check the clutch plates for flatness and fit on clutch hub serrations Discard any plate that does not slide freely on serrations or that is not flat 6 Check clutch hub thrust surfaces for scores and clutch hub splines for wear 7 Remove the No 2 forward clutch bearing Item Part Number Description 1 7D044 Reverse clutch drum 2...

Page 2506: ...8 Remove the reverse clutch selective retaining ring 9 Remove the reverse clutch pack 10 Using the special tools compress the reverse clutch piston spring ...

Page 2507: ...on spring pressure ring 1 Remove the reverse clutch piston spring 2 Remove the reverse clutch piston spring pressure ring 13 NOTE To ease reverse clutch piston removal it may be necessary to apply air pressure to the reverse clutch drum Block the opposite hole Remove the reverse clutch piston ...

Page 2508: ...all new if necessary Inspect the check balls for freedom of movement and correct seating 3 Check the clutch release spring for distortion and cracks Install a new spring including wave spring if distorted or cracked 4 Inspect the composition clutch plates steel clutch plates and clutch pressure plate for worn or scored bearing surfaces Install new parts if they are deeply scored or burred 5 Check ...

Page 2509: ...using even pressure to push it to the bottom of the reverse clutch drum 9 NOTE The dished side of the reverse clutch piston spring must face the reverse clutch piston Install the reverse clutch piston spring 1 Install the reverse clutch piston spring pressure ring 2 Install the reverse clutch piston spring 10 Using the special tools compress the reverse clutch piston spring ...

Page 2510: ...ool 13 CAUTION Install the pressure plates with the flat sides facing the clutch pack NOTE Before assembly soak the new clutch discs in clean automatic transmission fluid for 15 minutes Install the reverse clutch front pressure plate clutch pack and reverse clutch rear pressure plate ...

Page 2511: ...al tool check the reverse clutch pack clearance 1 Lift up on the clutch pack until it fully seats against the reverse clutch pressure plate retainer 2 Read the dial indicator If clearance is not within specifications install the correct size retaining ring Selective Retaining Rings Specification 1 52 1 62 mm 0 060 0 064 inch 1 87 1 98 mm 0 074 0 078 inch 2 23 2 33 mm 0 088 0 092 inch 2 59 2 69 mm ...

Page 2512: ...17 Check the clutch for correct operation Apply air pressure to the reverse clutch drum The clutch should be heard and felt to work without leakage ...

Page 2513: ...2003 Mustang Workshop Manual Special Tool s Dial Indicator Gauge with Holding Fixture 100 002 TOOL 4201 C or equivalent Compressor Clutch Spring 307 096 T81P 70235 A Protector Transmission Forward Clutch Outer Fluid Seal 307 423 Material Item Specification MERCON V Automatic Transmission Fluid XT 5 QM XT 5 DM MERCON V Item Part Number Description ...

Page 2514: ...tch plates for flatness and fit on clutch hub serrations Discard any plate that does not slide freely on serrations or that is not flat 6 Check the clutch hub thrust surfaces for scores and clutch hub splines for wear 7 NOTE The forward clutch hub may remain in the shell during disassembly Remove the forward clutch hub and the No 3 forward clutch hub front bearing 1 7F207 Forward clutch cylinder a...

Page 2515: ...pack selective retaining ring 9 Remove the following components 1 Remove the pressure plate 2 Remove the clutch pack 3 Remove the pressure spring 10 CAUTION Apply only enough pressure to release pressure on the retaining ring If too much pressure is applied the spring may break Using the special tool remove the forward clutch retaining ring ...

Page 2516: ...ard clutch from the press 12 Remove the forward clutch retainer and the return spring 13 NOTE Air pressure may be required to remove the forward clutch piston Remove the forward clutch piston 14 Remove the inner and outer forward clutch piston seals ...

Page 2517: ...t check balls for freedom of movement and correct seating 3 Check the clutch release spring for distortion and cracks Install a new spring including the wave spring if distorted or cracked 4 Inspect composition clutch plates steel clutch plates and clutch pressure plate for worn or scored bearing surfaces Install new parts if they are deeply scored or burred 5 Check the clutch plates for flatness ...

Page 2518: ...clutch piston 9 Using the special tools install the forward clutch piston into the clutch drum Push the piston to the bottom of the drum using even pressure 10 Using the special tool compress the piston return spring and install the retaining ring 11 Slowly release the press pressure and remove the forward clutch ...

Page 2519: ...etaining ring 14 Install the special tool on the forward clutch pack Push downward on the clutch pack Release pressure and zero the dial indicator 15 Using the special tool check the clutch pack clearance 1 Lift up on the clutch pack until it fully seats against the clutch pressure plate retainer 2 Read the dial indicator If the clearance is not within specifications install the correct size retai...

Page 2520: ...ut seals on the input shaft 17 Install the two scarf cut seals on the input shaft 18 Install the No 3 forward clutch hub front bearing and the forward clutch hub 1 52 1 62 mm 0 060 0 064 inch 1 87 1 98 mm 0 074 0 078 inch 2 24 2 34 mm 0 088 0 092 inch 2 59 2 69 mm 0 102 0 106 inch ...

Page 2521: ......

Page 2522: ...ct the rollers and springs for excessive wear or damage Inspect the spring and cage for bent or damaged spring retainers Rotate the center support counterclockwise and lift to remove the planetary gear support 2 Remove the planetary one way clutch SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Item Part Number Description 1 7A130 Planetary gear support 2 7A089 Planeta...

Page 2523: ...3 To assemble reverse the disassembly procedure ...

Page 2524: ... 2 Remove the forward clutch sun gear assembly and the No 5 forward clutch sun gear bearing and race Assembly SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Item Part Number Description 1 7C096 Forward clutch hub bearing No 4 2 7F244 Forward clutch sun gear bearing No 5 3 7A399 Forward clutch sun gear 4 7A019 Reverse sun gear assembly ...

Page 2525: ...1 The forward clutch sun gear and reverse sun gear assembly are assembled as part of the transmission assembly procedure ...

Page 2526: ...led View SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Special Tool s Compressor Clutch Spring 307 015 T65L 77515 A Protector Piston Seal 307 080 T80L 77234 A Protector Transmission Direct Clutch Outer Fluid Seal 307 422 Material Item Specification MERCON V Automatic Transmission Fluid XT 5 QM XT 5 DM MERCON V ...

Page 2527: ...Item Part Number Description 1 7F236 Direct clutch hub 2 7F243 No 7 direct clutch bearing 3 7D483 Direct clutch pressure plate retaining ring 4 7F237 Direct clutch inner bearing support 5 7B066 Direct clutch pressure plate 6 7B442 Direct clutch external spline plates steel 7 7B164 Direct clutch internal spline plates friction 8 388104 S2 Retaining ring 9 7F235 Direct clutch retainer and spring ass...

Page 2528: ...k on the output shaft must be aligned with the index mark on the output shaft ring gear during the assembly procedure Remove the ring gear snap ring 2 Separate the ring gear and output shaft 3 Remove the three output shaft seal rings ...

Page 2529: ...dly scored or damaged 8 Check the fluid passage in the clutch cylinder for obstructions Clean out all fluid passages Inspect the clutch piston for scores and install new if necessary Inspect the check balls for freedom of movement and correct seating 9 Check clutch release spring for distortion and cracks Install a new spring including wave spring if distorted or cracked 10 Inspect composition clu...

Page 2530: ...h pack 1 Remove the selective retaining ring 2 Remove the direct clutch pack 14 Using the special tool compress the piston return spring and remove the snap ring 15 WARNING Wear safety glasses when using compressed air NOTE If necessary use regulated compressed air 207 kPa 30 psi max pressure to remove the clutch piston Remove the support and spring assembly and piston ...

Page 2531: ...al 17 Remove the outer piston seal Assembly 1 NOTE Lubricate direct clutch piston inner seal and seal protector with petroleum jelly Using the special tool install the inner piston seal Install the seal with sealing lip facing down ...

Page 2532: ...install the direct clutch piston 4 Install the piston return spring and retainer assembly 5 Using the special tool compress the piston return spring and install the retaining ring 6 NOTE Before assembly soak new clutch discs in clean automatic transmission fluid for 15 minutes Install the clutch pack retaining ring 1 Alternate external spline steel plates and internal spline friction plates starti...

Page 2533: ...ifications install the correct size retaining ring and recheck the clearance 8 Install the direct clutch hub 1 Install the No 7 direct clutch inner bearing support 2 Install the direct clutch hub Selective Retaining Ring Specification 1 52 1 62 mm 0 060 0 064 inch 1 87 1 98 mm 0 074 0 078 inch 2 24 2 34 mm 0 088 0 092 in 2 59 2 69 mm 0 102 0 106 inch ...

Page 2534: ...lines for wear Inspect all bushings 9 CAUTION Make sure the seals are lapped correctly Internal damage may occur Install the two direct clutch seal rings 10 Install the output shaft hub Position the output shaft hub Install the retaining ring 11 Install the three output shaft seal rings ...

Page 2535: ...ut shaft ring gear is installed to the output shaft hub Assemble the direct clutch on the output shaft 14 CAUTION The index mark on the output shaft must be aligned with the index mark on the output shaft ring gear Align the index marks on output shaft and the output shaft ring gear and install the ring gear on the output shaft ...

Page 2536: ......

Page 2537: ...verter is found to be out of specification when carrying out one of the following torque converter checks One Way Clutch Check End Play Check Stator to Turbine Interference Check Stator to Impeller Interference Check Torque Converter Leak Check Evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes Major metallic failure Multiple clutc...

Page 2538: ...oughly cleaned by forward and backward flushing For additional information refer to Transmission Fluid Cooler Backflushing and Cleaning in this section 3 All cooler lines must be thoroughly cleaned by backward and forward flushing For additional information refer to Transmission Fluid Cooler Backflushing and Cleaning in this section 4 All Cooler Bypass Valves CBV if equipped must be thoroughly cle...

Page 2539: ......

Page 2540: ...uitable torque converter fluid cooler cleaner clean and flush the torque converter 2 After flushing drain the remainder of the solvent 3 Add 1 9 liter 2 qt of clean transmission fluid to the converter and agitate by hand 4 Thoroughly drain the solution SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Material Item Specification MERCON V Automatic Transmission Fluid XT 5...

Page 2541: ...s Failure to follow these instructions may result in personal injury Install the torque converter with the installed special tool into the arbor press Secure the press apply enough force to seal the tool into the torque converter 4 NOTE Use clean dry shop air Apply air pressure to the valve on the special tool SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Special Too...

Page 2542: ...d around these areas to aid in diagnosis If a leak is found around the drain plug install a new drain plug and recheck the torque converter If any other leaks are present install a new or remanufactured torque converter 6 Remove the air hose Release pressure and then slowly release the press Remove the torque converter Remove the special tool ...

Page 2543: ......

Page 2544: ...ue converter on the front pump support with the splines on the one way clutch inner race engaging the mating splines of the front pump support 3 Hold the front pump support stationary and rotate the torque converter counterclockwise The torque converter should rotate freely with no signs of scraping If there are signs of scraping install a new or remanufactured torque converter SECTION 307 01 Auto...

Page 2545: ......

Page 2546: ...ve hub and zero the dial indicator 3 Lift up on the special tool and note the dial indicator reading If the reading exceeds end play limits install a new or remanufactured torque converter SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Special Tool s Dial Indicator Gauge with Holding Fixture 100 002 TOOL 4201 C or equivalent End Play Gauge Torque Converter 307 071 T80...

Page 2547: ...4 Remove the special tools New or Rebuilt Torque Converter Used Torque Converter 0 355 1 04 mm 0 014 0 041 inch Max 0 355 1 87 mm 0 014 0 074 inch Max ...

Page 2548: ...clockwise while holding the special tool stationary The converter should lock up and hold torque The torque converter one way clutch should rotate freely in the clockwise direction Try the clutch for lockup and hold in at least five positions SECTION 307 01 Automatic Transaxle Transmission 2003 Mustang Workshop Manual Special Tool s Holding Tool One Way Clutch 307 062 T76L 7902 C or equivalent Hol...

Page 2549: ...If the torque converter fails the lockup test torque install a new or remanufactured torque converter ...

Page 2550: ...ate the forward clutch cylinder and shaft The turbine and torque converter clutch assemblies should rotate in both directions not exceeding maximum torque of 9 5 Nm 7 lb ft without any signs of metallic interference or scraping noise 5 If interference exists the stator front thrust washer may be worn allowing the stator to hit the turbine In such cases a new or remanufactured torque converter must...

Page 2551: ......

Page 2552: ...lding Fixture 100 002 TOOL 4201 C Rubber Tip Air Nozzle 100 D009 D93L 7000 A Alignment Gauge TR Sensor 307 351 T97L 70010 A Slide Hammer 100 001 T50T 100 A Installer Shift Shaft Fluid Seal 307 050 T74P 77498 A Shim Selection Gauge 307 072 T80L 77003 A Installer Servo Piston 307 073 T80L 77030 A Remover Installer Transmission Extension Housing ...

Page 2553: ...Air Test Plate Transmission 307 246 T92P 7006 A Remover Installer Servo Piston 307 251 T92P 70023 A Retainer Torque Converter 307 346 T97T 7902 A Installer Transmission Extension Housing Oil Seal 308 002 T61L 7657 A Gauge Transmission Solenoid Connectors 307 426 Material Item Specification Multi Purpose Grease ESB M1C93 ...

Page 2554: ...m jelly during subassembly buildup or transmission assembly Many components and surfaces in the transmission are precision machined Careful handling during disassembly cleaning inspection and assembly can prevent unnecessary damage to machined surfaces 1 Use the special tools to install the rear case bushing if removed 1 Position the rear case bushing and the special tool inside the case 2 Assembl...

Page 2555: ... the direct clutch 7 NOTE The reverse band support retaining ring is used for assembly purposes during production The reverse band support retaining ring is not required during assembly and it will not affect the operation of the transmission Install the reverse band support retaining ring ...

Page 2556: ... ring groove Install the planetary assembly and planetary gear support as a unit Rotate the output shaft to fully seat the planetary assembly 10 NOTE The planet support spring must be compressed and installed below the snap ring groove When the planet support spring is installed correctly both ends of the spring will be visible Install the case to the planet support spring located at the 1 o clock...

Page 2557: ...gear the No 5 forward clutch sun gear bearing and the reverse sun gear 13 Install the No 4 forward clutch hub bearing 14 Install the intermediate stub shaft 15 Install the forward clutch hub and the No 3 forward clutch hub front bearing ...

Page 2558: ...inder lugs are completely seated in the notches of the reverse sun gear Install the reverse clutch cylinder assembly 1 Install the reverse clutch cylinder 2 Install the No 2 forward clutch bearing 18 Install the overdrive band Position the overdrive band pocket onto the anchor pin ...

Page 2559: ...pring 2 Install the overdrive servo piston 20 Verify the tip of the piston assembly engages the pocket of the overdrive band 21 Using the special tool compress the overdrive servo assembly and install the overdrive servo retaining ring 22 Install the intermediate clutch pressure plate ...

Page 2560: ...the pump case mounting surface 2 Maintaining downward pressure use a depth micrometer to measure and verify intermediate clutch clearance is within specification If the intermediate clutch is not within specification install a correct selective plate 25 Install the intermediate anti rattle clip if equipped Selective Steel Plates Specification 1 80 1 70 mm 0 071 0 067 inch 2 05 1 95 mm 0 081 0 077 ...

Page 2561: ...ll the No 1 front pump support thrust washer Use petroleum jelly to hold the washer in place No 1 Thrust Washer Chart Depth Thickness Color Code 37 706 38 184 mm 1 485 1 503 inch 1 270 1 372 mm 0 050 0 054 inch Green 38 185 38 641 mm 1 504 1 521 inch 1 727 1 829 mm 0 068 0 072 inch Yellow 38 642 39 073 mm 1 522 1 538 inch 2 159 2 261 mm 0 085 0 089 inch Natural 39 074 39 505 mm 1 539 1 555 inch 2 ...

Page 2562: ... the case 29 NOTE Make sure the gasket is positioned correctly and the case passages are not covered Install the pump gasket 30 NOTE To aid assembly shake the input shaft while pushing down on the pump Install the pump assembly 31 Remove the alignment pin and install the front pump bolts Alternate bolt tightening to set the pump ...

Page 2563: ... the parking pawl return spring 2 Position the parking pawl 3 Install the parking pawl shaft 34 Install a new extension housing gasket and the extension housing 1 Position the extension housing 2 Install the four bolts and two nuts 35 Using the special tool install a new extension housing seal ...

Page 2564: ...l the bolt 37 Using the special tool install the manual control lever seal 38 NOTE Lubricate the electronic pressure control EPC solenoid O rings with clean automatic transmission fluid Install the EPC solenoid 1 Install the EPC solenoid 2 Install the EPC solenoid bracket and bolt ...

Page 2565: ...nual control shaft into the case 2 Install the manual lever shaft inner nut 3 Install the manual lever shaft retaining pin 41 Install the 1 2 accumulator piston assembly 1 Install the 1 2 accumulator upper spring 2 Install the 1 2 accumulator 3 Install the 1 2 accumulator lower spring 4 Install the 1 2 accumulator cover and seal ...

Page 2566: ...ation becomes necessary or when a new reverse band has been installed the reverse piston and rod length must be adjusted NOTE Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal NOTE Do not install the reverse servo piston cover and seal at this time Install the reverse servo piston and rod assembly 44 Install the special tool Tighten the bolt ...

Page 2567: ...the dial indicator 46 Loosen the bolt until the piston stops against the tool 47 Verify that the amount of piston travel on the dial indicator is within specification 48 If piston travel is not within specification select and install the correct servo assembly to bring the servo piston travel within specification ...

Page 2568: ...ves 49 Remove the special tools 50 Install the reverse servo piston cover and seal assembly 51 Using the special tool install the reverse servo retaining ring 1 Compress the reverse band servo 2 Install the reverse band servo retaining ring ...

Page 2569: ...ulated air pressure to the test ports Verify that the components are applied and released 54 NOTE The tab on the electrical connector is secured by main control valve body Install the electrical connector into the case 55 NOTE The alignment bolts are valve body assembly bolts and are in the valve body Align the main control valve body alignment bolts and position the main control valve body ...

Page 2570: ...ody bolts will be tightened in later steps Loosely install the 11 long main control valve body bolts 57 NOTE The main control valve body bolts will be tightened in later steps Loosely install the 12 short main control valve body bolts ...

Page 2571: ...58 Install the manual control valve detent lever spring 1 Position the manual control valve detent lever spring 2 Install the bolt 59 Tighten the bolts in the sequence shown ...

Page 2572: ... connector by pressing it in place by hand and fully seating the connector in place Connect the EPC solenoid by pressing it in place by hand and fully seating the connector in place Make sure that the terminals pass fully through the connector slots Connect the TCC by pressing it in place by hand and fully seating the connector in place Make sure that the terminals pass fully through the connector...

Page 2573: ...sition the pan magnet onto the fluid pan 64 NOTE The pan gasket is reusable clean and inspect for damage If not damaged the gasket should be reused Install the fluid pan 1 Position the transmission fluid pan 2 Install the 14 transmission fluid pan bolts ...

Page 2574: ...or 1 Install the digital TR sensor 2 Loosely install the digital TR bolts 66 NOTE The tool is designed to fit snugly NOTE Manual shift lever must be in the neutral position Using the special tool align the digital TR sensor slots 67 Tighten the bolts ...

Page 2575: ...ion is tipped CAUTION Make sure the converter hub is fully engaged in the front pump support and gear and rotates freely Do not damage the hub seal CAUTION If the torque converter slides out the hub seal may be damaged Using the special tools install the torque converter 70 Lubricate the torque converter pilot hub with multi purpose grease ...

Page 2576: ......

Page 2577: ...haft Position and secure the transmission on the high lift transmission jack 2 CAUTION Make sure the torque converter is fully seated in the transmission before positioning the transmission to the engine Using the special tool install the transmission to the engine Align the orange balancing marks on the converter stud and the flexplate bolt hole 3 Reconnect the harness SECTION 307 01 Automatic Tr...

Page 2578: ...4 Install the bolts 5 Install the bolt 6 Install the bolts 7 Install the bolts ...

Page 2579: ...8 Install the bolts 9 Reconnect the connectors 10 Connect the transmission fluid cooler tubes 11 Install the shift cable ...

Page 2580: ...E The manual lever must be in the overdrive position Connect the shift cable at the manual lever 13 Install the starter 1 Position the starter 2 Install the bolts 3 Connect the wires 14 Install the four nuts ...

Page 2581: ... the connector 18 Install the dual converter Y pipe 19 NOTE The output shaft and the drive shaft are a balanced assembly Install the driveshaft Align the yellow dots and position the driveshaft on the transmission Position the driveshaft to the rear differential ...

Page 2582: ...he transmission was overhauled and the vehicle was not equipped with an in line fluid filter install a new in line fluid filter kit If the transmission is being installed for a non internal repair do not install an in line filter or filter kit If installing a Ford authorized remanufactured transmission install the in line transmission fluid filter that is supplied Prior to lowering the vehicle ins...

Page 2583: ...le the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km 10 miles or more until the vehicle relearns the strategy Connect the battery ground cable 24 If required fill the transmission with clean automatic transmission fluid 25 Check the transmission for correct operation ...

Page 2584: ...hop Manual General Specifications Item Specification Fluid MERCON V Automatic Transmission Fluid XT 5 QM MERCON V Torque Specifications Description Nm lb ft Fluid cooler tube nut at radiator 32 24 Cooler line bracket to engine nut 48 35 Fluid cooler tube nut at transmission 21 15 ...

Page 2585: ...ler transfers heat from the transmission fluid to the engine coolant For transmission fluid cooler flow test refer to Section 307 01 For transmmission fluid cooler backflushing and cleaning refer to Section 307 01 Transmission Fluid Cooler Tubes SECTION 307 02 Transaxle Transmission Cooling 2003 Mustang Workshop Manual Item Part Number Description 1 Fluid cooler inlet tube 2 Fluid cooler outlet tu...

Page 2586: ......

Page 2587: ...e found install an entire new radiator For additional information refer to Section 303 03A or Section 303 03B Symptom Chart SECTION 307 02 Transaxle Transmission Cooling 2003 Mustang Workshop Manual SYMPTOM CHART Condition Possible Sources Action Transmission Overheating Damaged radiator REPAIR or install a new radiator For additional information REFER to Section 303 03A or Section 303 03B System ...

Page 2588: ......

Page 2589: ...hicle For additional information refer to Section 100 02 3 Remove the nuts 4 Remove the fluid cooler tube bracket at the engine 5 NOTE Use a backup wrench to hold the case fitting secure Remove the fluid cooler tubes at the transmission Installation SECTION 307 02 Transaxle Transmission Cooling 2003 Mustang Workshop Manual ...

Page 2590: ...ansmission 2 Install the fluid cooler tube bracket at the engine 3 Install the nuts 4 Lower the vehicle 5 Connect the battery cables 6 Fill the transmission with fluid and verify proper operation Use Motorcraft MERCON V Automatic Transmission Fluid XT 5 QM or equivalent meeting MERCON V specification ...

Page 2591: ......

Page 2592: ...TION 307 05 Automatic Transaxle Transmission External Controls 2003 Mustang Workshop Manual Torque Specifications Description Nm lb ft lb in Steering Column Nuts 40 30 Shift Interlock Cable 7 62 Shift Cable Bracket 12 9 ...

Page 2593: ...ey interlock assembly and necessary wiring The shift lock actuator is energized when the ignition switch is turned to the run position locking the floor mounted transmission range selector lever in the PARK position When the brake pedal is depressed the shift lock actuator is deactivated and the floor mounted transmission range selector lever can be moved out of the PARK position Transmission Cont...

Page 2594: ...m GO to Symptom Chart Symptom Chart SECTION 307 05 Automatic Transaxle Transmission External Controls 2003 Mustang Workshop Manual Special Tool s 73 Digital Multimeter 105 R0051 or equivalent Visual Inspection Chart Mechanical Electrical Shift control linkage binding Shift lock actuator Shift control cable Interlock cable Circuitry Central junction box CJB fuse 17 15A 28 15A 35 15A Brake pedal pos...

Page 2595: ... Transmission Control Switch TCS Is Inoperative CJB Fuse 28 15A TCS TCS not cycled during self test Powertrain control module PCM Circuitry Go To Pinpoint Test C The Transmission Control Indicator Lamp TCIL Is Not Operating Correctly Bulb Instrument cluster Powertrain control module REFER to Section 413 01 Excessive Shift Effort Transmission shift cable INSTALL a new transmission shift cable Cable...

Page 2596: ...ircuit TEST the system for normal operation A3 CHECK CIRCUIT 294 WH LB FOR AN OPEN Key in ON position Measure the voltage between shift lock actuator C2127 1 Circuit 294 WH LB harness side and ground Is the voltage greater than 10 volts Yes GO to A4 No REPAIR the circuit TEST the system for normal operation A4 TEST CIRCUIT 1205 BK FOR AN OPEN Measure the resistance between shift lock actuator C212...

Page 2597: ...stem for normal operation B3 CHECK THE LINKAGE CABLE FOR CORRECT GEAR RELATIONSHIP Apply the brake pedal Actuate the transmission range selector lever in all ranges Does the indicator match the gear selection Yes VERIFY the correct adjustment of the digital transmission range DTR sensor REFER to Section 307 01 Adjust the digital DTR sensor if necessary TEST the system for normal operation No ADJUS...

Page 2598: ...00 ohms with the TCS released Yes GO to C3 No INSTALL a new TCS Test the system for normal operation C3 CHECK CIRCUIT 224 TN WH FOR AN OPEN Key in OFF position Disconnect PCM C175 Measure the resistance between TCS C279 4 Circuit 224 TN WH harness side and PCM C175 29 Circuit 224 TN WH harness side Is the resistance less than 5 ohms Yes REFER to Powertrain Control Emissions Diagnosis PC ED manual ...

Page 2599: ......

Page 2600: ... lever in the overdrive position 2 Raise and support the vehicle For additional information refer to Section 100 02 3 Loosen the manual control lever nut 4 Place the transmission manual control lever in the overdrive position 5 Tighten the nut on the manual control lever SECTION 307 05 Automatic Transaxle Transmission External Controls 2003 Mustang Workshop Manual ...

Page 2601: ......

Page 2602: ...Actuator Removal 1 Remove the shifter top control panel 2 Disconnect the electrical connectors 3 Remove the shifter bezel 4 Remove the bulb from the bezel SECTION 307 05 Automatic Transaxle Transmission External Controls 2003 Mustang Workshop Manual ...

Page 2603: ...rce may be needed to lift up on the handle Do not to pull too far or damage to the overdrive cancel button may result as the wires may be pulled out of the switch Remove the screw and the handle 7 Remove the clip and bolt from the brake shift interlock cable ...

Page 2604: ...ent panel steering column cover 1 Remove the screws 2 Remove the instrument panel steering column cover 10 Remove the instrument panel reinforcement 1 Remove the screws 2 Remove the instrument panel reinforcement 11 Remove the nuts and lower the steering column ...

Page 2605: ...12 Remove the screws from the brake shift interlock cable 13 Remove the brake shift cable interlock actuator Installation 1 To install reverse the removal procedure ...

Page 2606: ......

Page 2607: ...00 02 2 Remove the cable shift from the shifter lever and bracket and discard the clip 3 Remove the bolt from the cable 4 Remove the bolt from the cable 5 Disconnect the transmission range selector lever cable from the TR sensor lever SECTION 307 05 Automatic Transaxle Transmission External Controls 2003 Mustang Workshop Manual ...

Page 2608: ...ssion shift cable bracket 7B229 from the transmission 1 Remove the bolts 2 Remove the bracket Installation 1 NOTE It is necessary to install a new plastic clip prior to installation To install reverse the removal procedure ...

Page 2609: ......

Page 2610: ... Removal 1 Remove the shifter top control panel 2 Disconnect the electrical connectors 3 Remove the shifter bezel 4 Remove the bulb from the bezel SECTION 307 05 Automatic Transaxle Transmission External Controls 2003 Mustang Workshop Manual ...

Page 2611: ... Do not to pull too far or damage to the overdrive cancel button may result as the wires may be pulled out of the switch Remove the screw and the handle 7 Raise and support the vehicle For additional information refer to Section 100 02 8 Disconnect the shift cable and discard the plastic clip ...

Page 2612: ...9 Lower the vehicle 10 Remove the shifter Installation 1 NOTE It is necessary to install a new plastic clip prior to installation To install reverse the removal procedure ...

Page 2613: ......

Page 2614: ...Switch Removal 1 Remove the shifter top control panel 2 Disconnect the electrical connectors 3 Remove the shifter bezel 4 Remove the bulb from the bezel SECTION 307 05 Automatic Transaxle Transmission External Controls 2003 Mustang Workshop Manual ...

Page 2615: ...Extra force may be needed to lift up on the handle Do not to pull too far or damage to the overdrive cancel button may result as the wires may be pulled out of the switch Remove the screw and the handle 7 Remove the transmission control switch ...

Page 2616: ...Installation 1 To install reverse the removal procedure ...

Page 2617: ...val 1 Remove the shifter top control panel 2 Disconnect the electrical connectors 3 Remove the shifter bezel 4 Remove the bulb from the bezel SECTION 307 05 Automatic Transaxle Transmission External Controls 2003 Mustang Workshop Manual ...

Page 2618: ...needed to lift up on the handle Do not to pull too far or damage to the overdrive cancel button may result as the wires may be pulled out of the switch Remove the screw and the handle 7 Remove the bezel Installation 1 To install reverse the removal procedure ...

Page 2619: ......

Page 2620: ...ditional information refer to Section 501 12 2 Remove the bolts then position the bezel upward 3 Remove the bulb socket from the bezel 4 Remove the bulb 5 To install reverse the removal procedure SECTION 307 05 Automatic Transaxle Transmission External Controls 2003 Mustang Workshop Manual ...

Page 2621: ......

Page 2622: ...val 1 Remove the shifter top control panel 2 Disconnect the electrical connectors 3 Remove the shifter bezel 4 Remove the bulb from the bezel SECTION 307 05 Automatic Transaxle Transmission External Controls 2003 Mustang Workshop Manual ...

Page 2623: ...Extra force may be needed to lift up on the handle Do not to pull too far or damage to the overdrive cancel button may result as the wires may be pulled out of the switch Remove the screw and the handle 7 Remove the transmission control switch ...

Page 2624: ...Installation 1 To install reverse the removal procedure ...

Page 2625: ...le Sensor spring Belleville Clutch Disc 3 8L Clutch diameter 280 mm 11 0 inches Number of springs 5 Color identification none Clutch Disc 4 6L 2V Clutch diameter 280 mm 11 0 inches Number of springs 4 Color identification none Lubricants Spec and Capacity Fluid T50D MERCON Multi Purpose ATF Transmission Fluid XT 2 QDX 2 6L 2 8 qt TR3650 Synthetic MERCON ATF Transmission Fluid E6AZ 19582 B 3 6L 7 5...

Page 2626: ...Section 308 01 Clutch Disc and Clutch Pressure Plate 3 8L SECTION 308 00 Manual Transaxle Transmission and Clutch General Information 2003 Mustang Workshop Manual Item Part Number Description 1 6397 Flywheel housing to block dowel 2 req d 2 Rear face of block and flywheel part of 6010 3 6397 Flywheel to clutch pressure plate dowel 3 req d 4 7600 Pilot bearing 5 7550 Clutch disc 6 7563 Clutch press...

Page 2627: ...13 55981 S36M Bolt 14 7513 Clutch release lever dust shield 15 N807508 S2 Screw and washer assembly Item Part Number Description 1 6375 Flywheel 2 6397 Flywheel to clutch pressure plate dowel 3 req d 3 7600 Pilot bearing 4 7550 Clutch disc 5 7563 Clutch pressure plate 6 7515 Clutch release lever 7 7B602 Clutch release lever stud 8 N606063 S2 Bolt 6 req d 9 6392 Flywheel housing 10 55981 S36M Bolt ...

Page 2628: ...friction is directly related to the composition of the facing material and the magnitude of the clamping 12 7548 Clutch release hub and bearing 13 N808969 S100 Bolt 14 N808969 S100 Bolt 6 req d 15 Rear face of block and flywheel part of 6010 16 Bolt 3 req d 17 6397 Flywheel housing to block dowel 2 req d Item Part Number Description 1 6375 Flywheel 2 7600 Pilot bearing 3 7550 Clutch disc 4 7563 Cl...

Page 2629: ...heel The clutch system is disengaged when the clutch pedal is pressed and is accomplished when the release fingers are fully displaced toward the flywheel This displacement removes the spring load from the clutch pressure plate and eliminates the coupling friction between the engine and the transmission When the clutch pedal is depressed a cable connected to the clutch release lever hub and bearin...

Page 2630: ... at different engine rpm Symptom Chart SECTION 308 00 Manual Transaxle Transmission and Clutch General Information 2003 Mustang Workshop Manual Symptom Chart Condition Possible Sources Action Clutch slippage Clutch pedal sticking Pressure plate diaphragm spring damaged or weakened Clutch pressure plate damaged Clutch disc facing damaged or worn excessively Clutch disc facing surface hardened or oi...

Page 2631: ...plate to flywheel bolts Go To Pinpoint Test C Clutch pedal pulsation Clutch disc damaged or worn Excessive flywheel runout Loose pressure plate to flywheel bolts Improperly assembled release lever to pivot stud Go To Pinpoint Test D Clutch related vibrations Engine component grounding against frame Loose flywheel bolts Excessive flywheel runout Imbalanced clutch pressure plate Accessory drive belt...

Page 2632: ... components as necessary REFER to Section 308 03A or Section 308 03B Loose pressure plate to flywheel bolts CHECK for loose bolts at the pressure plate INSTALL new components as necessary REFER to Section 308 01 NOTE While verifying the condition determine whether the noise is gear rollover noise release bearing rub or some other transmission related noise Gear rollover noise inherent in manual tr...

Page 2633: ...INSPECT the gears and gear teeth for wear or damage INSTALL new components as necessary REFER to Section 308 01 Gears clash when shifting from one forward gear to another Pilot bearing CHECK for a binding condition between the input shaft and the engine crankshaft pilot bearing INSTALL new components as necessary REFER to Section 308 01 Gear teeth and or synchronizer REPAIR or INSTALL new componen...

Page 2634: ...nsmission will not shift into one gear all others OK Manual shift linkage REPAIR or INSTALL new components as necessary Backup switch ball If REVERSE is the problem CHECK backup switch for ball frozen in extended position Internal components INSPECT the shift rail and fork system synchronizer system and the gear clutch teeth for restricted travel REPAIR or INSTALL new components as necessary Trans...

Page 2635: ...s necessary REFER to Section 308 03A or Section 308 03B Fill and drain plugs CHECK fill and drain plugs and bore threads REPAIR as necessary TIGHTEN plugs to specified torque value REFER to Section 308 03A or Section 308 03B Bearing failure Other part failure Raceways or rollers Lubricant Towing vehicle further than 80 km 50 miles with driveshaft installed Mainshaft tapered bearing and needle cage...

Page 2636: ...s and slowly release the clutch pedal Does the clutch pedal release without binding Yes GO to A2 No INSPECT the clutch pedal REFER to Section 308 02 A2 CARRY OUT A STALL TEST Key in START position Block the wheels and apply the parking brake Place the transmission in fourth gear Increase the engine speed to 2000 rpm and slowly release the clutch pedal Does the engine stall within five seconds Yes ...

Page 2637: ... disc inspection procedure Refer to Disc Check Is the clutch disc OK Yes GO to B5 No INSTALL a new clutch disc REFER to Section 308 01 TEST the system for normal operation B5 INSPECT THE FLYWHEEL Inspect the flywheel for damage and runout Refer to Flywheel Runout Check Is the flywheel OK Yes GO to B6 No REPAIR or INSTALL a new flywheel as necessary REFER to Section 308 01 TEST the system for norma...

Page 2638: ...in START position With the transmission in NEUTRAL slowly press the clutch pedal Does the clutch pedal pulsate while being pressed Yes GO to D2 No VERIFY customer concern GO to Symptom Chart if necessary D2 INSPECT PRESSURE PLATE BOLTS Inspect the pressure plate to flywheel bolts Are any of the pressure plate to flywheel bolts loose Yes TIGHTEN or INSTALL new bolts REFER to Section 308 01 TEST the...

Page 2639: ...ounding Check for exhaust manifolds or other engine component grounding on the body or frame Is there evidence of grounding on the body or frame Yes REPAIR the components as necessary TEST the system for normal operation No GO to E2 E2 CHECK FOR ACCESSORY DRIVE VIBRATIONS Key in START position Remove the accessory drive belt Does the vibration stop when the accessory drive belt is removed from the...

Page 2640: ...he most upward position tighten the nut Was the clutch pedal incorrectly adjusted Yes VERIFY customer concern TEST the system for normal operation No GO to F3 F3 CHECK THE CLUTCH PEDAL QUADRANT Pull up on the clutch pedal to the upstop Pulling up on the pedal ensures that the quadrant is free to rotate through it s complete range of motion against the spring load of the quadrant Is the clutch peda...

Page 2641: ...move the shift lever forward a little more The transmission will behave as if in neutral but the reverse gear synchronizer will be bypassed With the clutch pedal up gently pull the shift lever toward the reverse gear position Gear clash can now be heard Slowly depress the clutch pedal Using the steering wheel inner seam as a reference note the measurement when the gear clash stops or the shift lev...

Page 2642: ...E BEARING Inspect the release bearing for wear or damage Make sure the release lever is seated in the release bearing pocket Is the release bearing worn or damaged Yes INSTALL a new release bearing TEST the system for normal operation No GO to F7 F7 INSPECT THE PILOT BEARING Inspect the pilot bearing for wear or damage Is the pilot bearing worn or damaged Yes INSTALL a new pilot bearing TEST the s...

Page 2643: ... affected gear Are there any internal components worn or damaged Yes INSTALL new components or REPAIR as necessary TEST the system for normal operation No ASSEMBLE and INSTALL the transmission TEST the system for normal operation Test Step Result Action to Take G1 TRANSMISSION NEUTRAL GEAR ROLLOVER TEST Start the engine and let it idle with the transmission in neutral and the clutch engaged pedal ...

Page 2644: ...No INSPECT the crankshaft end play REFER to Section 303 01A or Section 303 01B ...

Page 2645: ...le technicians should wear government approved toxic dust purifying respirators Failure to follow these instructions may result in personal injury WARNING Grinding or sanding on the brake linings pads rotors drums or clutch facings should be done only while using correct exhaust ventilated equipment Failure to follow these instructions may result in personal injury WARNING OSHA requires areas wher...

Page 2646: ...the clutch disc 5 Use an emery cloth to remove minor imperfections in the clutch disc lining surface 6 Check for wear or rust on the splines If necessary clean them with an emery cloth 7 Check the clutch disc 7550 for cracking scoring discoloration or other surface marks Install a new clutch disc as necessary ...

Page 2647: ......

Page 2648: ... Measure the flatness of the clutch pressure plate surface with a straightedge and a feeler gauge 3 Check the diaphragm spring fingers for discoloration scoring bent or broken segments and spring ends that are higher or lower than the rest 4 Measure the wear of the diaphragm spring fingers SECTION 308 00 Manual Transaxle Transmission and Clutch General Information 2003 Mustang Workshop Manual ...

Page 2649: ......

Page 2650: ...eck the flywheel surface for scoring cracks or discoloration Minor scratches or discoloration should be removed with a fine emery cloth SECTION 308 00 Manual Transaxle Transmission and Clutch General Information 2003 Mustang Workshop Manual ...

Page 2651: ...on the clutch disc contact surface 2 Turn the flywheel 6375 if the runout exceeds the maximum allowance install a new flywheel SECTION 308 00 Manual Transaxle Transmission and Clutch General Information 2003 Mustang Workshop Manual Special Tool s Dial Indicator Magnetic Base 100 D002 D78P 4201 B or equivalent ...

Page 2652: ...eaning fluid Inspect the pilot bearing 7118 for 1 needle rollers for scoring worn or broken rollers cracked roller cage inadequate grease or discoloration 2 seal leakage misalignment and looseness in the crankshaft SECTION 308 00 Manual Transaxle Transmission and Clutch General Information 2003 Mustang Workshop Manual ...

Page 2653: ... in an open hole and a pair of locking pliers where the flywheel dowel is installed in a blind hole Installation 1 NOTE Care should be taken to drive the flywheel dowel squarely into place until it is fully seated and to not damage the surrounding surface areas Install all flywheel dowels by driving them into place using a brass or plastic mallet SECTION 308 00 Manual Transaxle Transmission and Cl...

Page 2654: ...ck dowel is installed in an open hole and a pair of locking pliers where the flywheel housing to block dowel is installed in a blind hole Installation 1 NOTE Care should be taken to drive the flywheel housing to block dowel squarely into place until it is fully seated without damaging the surrounding surface areas Install all flywheel housing to block dowels by driving them into place using a bras...

Page 2655: ......

Page 2656: ...of springs 5 plain Color identification none Clutch diameter 4 6L 2V 280 mm 11 0 in Number of springs 4 plain Color identification none Clutch diameter 4 6L 4V 280 mm 11 0 in Number of springs 5 plain Color identification no paint daub Fluid and Lubricants Motorcraft Premium Long Life Grease XG 1 C or equivalent ESA M1C75 B Torque Specifications Description Nm lb ft Pressure plate to flywheel bolt...

Page 2657: ......

Page 2658: ...clutch pressure plate These factors limit the amount of torque that can be transmitted without slippage The clamping force is obtained from a diaphragm spring contained within the clutch pressure plate assembly This force is developed during the attachment of the clutch pressure plate to the flywheel The clutch system is disengaged when the clutch pedal is depressed and engaged when the clutch ped...

Page 2659: ...DIAGNOSIS AND TESTING Clutch Refer to Section 308 00 SECTION 308 01 Clutch 2003 Mustang Workshop Manual ...

Page 2660: ...ts and remove the clutch pressure plate and the clutch disc Installation NOTE Clean the clutch pressure plate and flywheel with a commercial alcohol based solvent so surfaces are free from oil film Do not use cleaners with a petroleum base Do not immerse the clutch pressure plate in the solvent 1 Position the clutch disc on the flywheel Using the special tool align the clutch disc SECTION 308 01 C...

Page 2661: ...ate and install it on the dowels Install the bolts in the sequence shown Remove the special tool 3 NOTE Before installing the transmission the ball stud the clutch release lever and the input shaft must be cleaned and lubricated with grease Install the transmission For additional information refer to Section 308 03A T5OD or Section 308 03B TR3650 ...

Page 2662: ......

Page 2663: ...o 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 ...

Page 2664: ...e the seven bolts and the clutch housing 7 CAUTION Loosen the bolts evenly to prevent damage to the pressure plate NOTE If the pressure plate is to be reused index mark the pressure plate to the flywheel Remove the six bolts and the pressure plate and disc ...

Page 2665: ... installing the transmission the ball stud the clutch release lever and the input shaft must be cleaned and lubricated with grease To install reverse the removal procedure Using the special tool align the clutch disc and pressure plate to the flywheel 2 Tighten the pressure plate bolts in two stages Stage 1 Tighten the bolts to 45 Nm 33 lb ft Stage 2 Tighten the bolts an additional 60 degrees ...

Page 2666: ......

Page 2667: ... 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...

Page 2668: ......

Page 2669: ... flywheel Installation 1 WARNING This procedure should be carried out only by a properly equipped and experienced acetylene torch operator Tongs must be used or asbestos gloves worn when handling the heated flywheel ring gear Failure to follow these instructions can result in personal injury CAUTION Do not heat the flywheel ring gear beyond 261 C 500 F Use heat indicating crayons to prevent overhe...

Page 2670: ......

Page 2671: ...scription Nm lb ft lb in Brake booster nuts 25 18 Brake pedal support bracket to cowl bolt 25 18 Clutch pedal retaining nut 40 30 Clutch release lever cable bracket screw 3 8L 10 89 Clutch release lever cable to bulkhead screws 4 35 Clutch release lever cable to crossmember retaining screw 8 71 Clutch release lever cable to master cylinder retaining screw 4 6L 8 71 Instrument panel reinforcement s...

Page 2672: ......

Page 2673: ...N Clutch Controls SECTION 308 02 Clutch Controls 2003 Mustang Workshop Manual Item Part Number Description 1 7535 Clutch release lever cable 3 8L 2 7535 Clutch release lever cable 4 6L 3 11A152 Clutch pedal position CPP switch ...

Page 2674: ...urn 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 p...

Page 2675: ...DIAGNOSIS AND TESTING Clutch Controls Refer to Section 308 00 SECTION 308 02 Clutch Controls 2003 Mustang Workshop Manual ...

Page 2676: ... 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 ...

Page 2677: ...PP switch from the brake master cylinder push rod 3 Remove the brake master cylinder push rod spacers 2B129 4 Remove the brake master cylinder push rod bushing 2474 7 Disconnect the clutch pedal position CPP switch electrical connector 8 Disconnect the deactivation switch connector from the wiring harness ...

Page 2678: ...esult in personal injury NOTE Lift the clutch pedal all the way up to release the clutch release lever cable 7K553 Rotate the clutch pedal adjuster quandrant 7L583 and unhook the clutch release lever cable 7K553 10 Remove the nuts 11 Remove the screw 12 Remove the nut and the clutch pedal 7519 ...

Page 2679: ...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 ...

Page 2680: ......

Page 2681: ......

Page 2682: ...r installing the clutch release lever cable be followed Incorrect installation may damage components or cause system failure 1 Remove the instrument panel steering column cover 1 Remove the screws 2 Remove the instrument panel steering column cover 2 Remove the instrument panel reinforcement 1 Remove the screws 2 Remove the instrument panel reinforcement 3 Lift the clutch pedal 7519 to its most up...

Page 2683: ...juster quadrant 7L583 6 Open the hood remove the screws and the clutch release cable 7K553 7 NOTE On 4 6L vehicles only Remove the bolt and the clutch release lever cable bracket from the brake master cylinder 2140 8 Raise the vehicle For additional information refer to Section 100 02 9 Remove the screw from the clutch release lever cable clamp ...

Page 2684: ...e clutch release lever cable 7K553 and remove from the clutch release lever 7515 12 Remove the C clip from the clutch release lever cable and remove the clutch release lever cable from the vehicle Installation 1 To install reverse the removal procedure ...

Page 2685: ......

Page 2686: ......

Page 2687: ...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 re...

Page 2688: ...Bolt retaining crossmember to transmission support 58 43 Nut retaining dual converter Y pipe to exhaust manifold 40 30 Nut retaining dual converter Y pipe flange to muffler 35 26 Bolt retaining driveshaft centering yoke to pinion flange 112 83 ...

Page 2689: ...n fifth speed gear functions as an overdrive gear forward gears are synchronized and helical cut shift interlock system prevents the engagement of more than one gear Transmission Manual Five Speed SECTION 308 03A Manual Transaxle Transmission T5OD 2003 Mustang Workshop Manual ...

Page 2690: ...rt Number Description 1 E602162 S71 Bolt 2 N800037 S2 Bolt 3 87038 S91 O ring 4 7358 Main shift control shaft 5 7222 Case cover 6 74113 S Plug 7 7230 Gear shifter fork 1 2 shift 8 7L082 Gear shift fork insert ...

Page 2691: ... 7173 First gear bearing spacer 25 7127 First gear bearing 26 7100 First gear 27 7065 Output shaft rear bearing 28 7D234 Thrust bearing 29 7D235 Thrust washer 30 Synchronizer hub part of 7124 31 7124 Synchronizer assembly 32 7B340 Third gear 33 7B369 Third speed bearing 34 7B320 Third speed gear bearing spacer 35 7064 Snap ring 36 7119 Thrust washer 37 7102 Second gear 38 7728 Second speed gear be...

Page 2692: ...el stop 63 7141 Reverse idler gear and bushing 64 7140 Reverse idler gear shaft 65 357479 S15 Pin 66 7K316 Fifth speed driven gear 67 7H150 Output shaft speed wheel 68 7034 Vent 69 E800152 S72 Bolt 70 7A039 Extension housing 71 7K381 Extension plug 72 7052 Extension housing fluid seal 73 372720 S Detent ball 74 7234 Shifter detent spring 75 7F018 Gearshift offset lever 76 7K453 Gearshift shaft bus...

Page 2693: ...ag Item Part Number Description 1 Transmission assembly number 2 Build date code month 3 Build date code day 4 Build date code year 5 Shift Number 6 Serial number 7 Wg identification number Located on the extension housing bolt on the LH side of the transmission ...

Page 2694: ...DIAGNOSIS AND TESTING Manual Transmission Refer to Section 308 00 SECTION 308 03A Manual Transaxle Transmission T5OD 2003 Mustang Workshop Manual ...

Page 2695: ...emove the driveshaft For additional information refer to Section 205 01 3 Using the special tools remove the extension housing fluid seal Installation 1 Using the special tool install the extension housing fluid seal SECTION 308 03A Manual Transaxle Transmission T5OD 2003 Mustang Workshop Manual Special Tool s Installer Transmission Extension Housing Oil Seal 308 227 T94P 7657 A Slide Hammer 100 0...

Page 2696: ...2 CAUTION Align the index marks Install the driveshaft For additional information refer to Section 205 01 3 Check the transmission fluid level add fluid if necessary 4 Lower the vehicle ...

Page 2697: ... Remove the console panel gearshift plate Lift the gearshift lever boot over the gearshift lever 3 Remove the bolts and the shift lever SECTION 308 03A Manual Transaxle Transmission T5OD 2003 Mustang Workshop Manual Material Item Specification Clear Silicone Rubber D6AZ 19562 AA or equivalent ESB M4G92 A ...

Page 2698: ... 6 Remove the gearshift lever boot 7 CAUTION Cover the opening in the extension housing to prevent contamination Clean the gearshift lever mounting surfaces 8 To install reverse the removal procedure Apply a 3 2 mm 1 8 in bead of silicone rubber to the sealing surface on the gearshift lever ...

Page 2699: ......

Page 2700: ...n NEUTRAL raise and support the vehicle For additional information refer to Section 100 02 2 Disconnect the electrical connector 3 Remove the output shaft speed OSS sensor 4 To install reverse the removal procedure SECTION 308 03A Manual Transaxle Transmission T5OD 2003 Mustang Workshop Manual ...

Page 2701: ......

Page 2702: ...ift lever knob 7213 4 Remove the console panel gearshift plate Lift the gearshift lever boot over the gearshift lever 7210 5 Remove the bolts and the shift lever 6 Raise and support the vehicle For additional information refer to Section 100 02 7 Disconnect the heated oxygen sensor electrical connectors SECTION 308 03A Manual Transaxle Transmission T5OD 2003 Mustang Workshop Manual ...

Page 2703: ...way 9 Remove the LH nuts 10 Remove the RH nuts 11 Remove the dual converter Y pipe 12 CAUTION Index mark the driveshaft flange and pinion flange and the driveshaft slip yoke and transmission output shaft Remove the driveshaft For additional information refer to Section 205 01 ...

Page 2704: ...rness from the transmission 14 Remove the starter motor 11001 For additional information refer to Section 303 06 15 Disconnect the output shaft speed sensor OSS electrical connector Disconnect the wiring harness from the transmission 16 Remove the bolt and the clutch release lever cover ...

Page 2705: ...elease cable from the clutch release fork 18 Remove the clutch cable retainer and remove the clutch cable from the transmission 19 If transmission disassembly is necessary drain the transmission fluid 20 Position a transmission jack and support the transmission 21 Remove the bolts and the transmission crossmember ...

Page 2706: ...22 Remove the bolts 23 Lower the transmission and remove the five bolts ...

Page 2707: ......

Page 2708: ...ent and dry with compressed air During disassembly clean all components with solvent and dry with compressed air SECTION 308 03A Manual Transaxle Transmission T5OD 2003 Mustang Workshop Manual Special Tool s Bearing Puller 205 D064 D84L 1123 A or Equivalent Front Hub Tool 204 069 T81P 1104 C Holding Fixture 307 003 T57L 500 B Impact Slide Hammer 100 001 T50T 100 A Puller 307 001 TOOL 1175 AC or Eq...

Page 2709: ...emove the bolts and the gearshift lever 6 CAUTION Do not attempt to remove the gearshift offset lever with the extension housing bolted in place A lug located on the bottom of the gearshift offset lever meshes with the detent plate preventing enough rearward movement of the gearshift offset lever to allow removal Remove the split pin and the gearshift shaft bushing ...

Page 2710: ...ication tag 9 CAUTION The gearshift offset lever is under spring pressure While applying downward pressure on the gearshift offset lever remove the extension housing and the gearshift offset lever as an assembly 10 Remove the gearshift offset lever the split pin the shifter detent spring and the detent ball ...

Page 2711: ...Remove the case cover Lift the case cover and slide it toward the filler plug side of the case to clear the reverse gearshift lever 13 CAUTION Support the reverse gear shift rail 7240 with a block of wood Remove the split pin ...

Page 2712: ...7 15 Remove the fifth speed cluster gear 7144 the synchronizer blocking ring 7107 the synchronizer assembly 7124 and the fifth gear shifter fork 7230 as an assembly 16 Remove the reverse gearshift lever retaining clip 17 NOTE Do not remove the reverse gearshift lever 7K002 at this time Using a TORX bit driver remove the shift lever reverse pin 7K024 ...

Page 2713: ...kwise to disengage the ball stud from the reverse gearshift lever 2 Pull the reverse gear shift rail rearward slightly 3 Rotate the reverse gear shift rail counterclockwise to align the ball stud with the slot in the case and remove the reverse gear shift rail 20 Remove the snap ring and the output shaft speed wheel 7H150 ...

Page 2714: ...D234 and the thrust washer 7D235 from the rear of the input shaft 7017 Remove the input shaft Rotate the input shaft until the flat on the fourth gear clutching teeth aligns with the countershaft cluster gear 7113 23 Remove the thrust washer the thrust bearing the input shaft bearing spacer and the 15 roller bearings 24 Remove the fourth speed synchronizer blocking ring 7107 ...

Page 2715: ...6 Remove the output shaft assembly 27 NOTE Observe the location of the reverse gearshift lever the reverse shift fork 7230 and the reverse positioning spring 7E485 NOTE Observe the rotation action of the reverse positioning spring Remove the reverse gearshift lever the reverse shift fork and the reverse positioning spring as an assembly Hold the reverse gearshift lever and lift it upward as straig...

Page 2716: ...140 the reverse idler gear and bushing 7141 and the reverse gear overtravel stop 7E397 30 Using the special tool flatten the tabs on the countershaft rear bearing retainer 7195 31 Remove the four bolts the countershaft rear bearing retainer and the shim 7L172 ...

Page 2717: ...e the race work the countershaft cluster gear back and forth Remove the bearing race 33 Using the special tools remove the rear countershaft bearing assembly 7F431 34 Move the countershaft cluster gear rearward through the bearing bore Tilt the assembly upward and remove it from the case ...

Page 2718: ......

Page 2719: ... center the gear shift plates and the selector body 7302 2 Rotate the main shift control shaft 7358 counterclockwise and pull it rearward to access the pin Remove the pin 3 Using a twisting motion remove the main shift control shaft 4 Remove the gear shifter forks the gear shift plates the pin the gear selector interlock sleeve and the selector body SECTION 308 03A Manual Transaxle Transmission T5...

Page 2720: ...ring N800037 S2 6 CAUTION Note the orientation of the gear shift plate for assembly reference Remove the gear shift plate and the gear shift fork inserts 7L082 from the shifter forks Assembly 1 Install the new O ring ...

Page 2721: ... petroleum jelly 5 NOTE The 1 2 gear shifter fork is the larger shifter fork The gear shifter fork offset lever must face the cover Position the gear shift plate attached to the 3 4 gear shifter fork under the gear shift plate attached to the 1 2 gear shifter fork Position the gear shifter forks and the main shift control shaft in the cover Slide the shaft through the cover and shift the component...

Page 2722: ...NOTE The flat on the main shift control shaft must face upward Install the pin ...

Page 2723: ... input bearing 7025 2 Remove the bearing race and the end play selective shims 3 Remove the input shaft seal 7052 Assembly SECTION 308 03A Manual Transaxle Transmission T5OD 2003 Mustang Workshop Manual Special Tool s Input Shaft Seal Replacer 308 220 T94P 7025 AH Pinion Bearing Cone Remover 205 D002 D79L 4621 A or Equivalent ...

Page 2724: ...OTE In installing a new input shaft seal as part of a transmission overhaul do not install the end play selective shims at this time Instal the end play selective shims and the bearing race 3 Using a press and a capped length of pipe install the input bearing ...

Page 2725: ......

Page 2726: ...nchronizer blocking ring 7107 and the third gear 7B340 as an assembly 2 Remove the third speed bearing 7B369 and the third speed gear bearing spacer 7B320 3 Remove the snap ring SECTION 308 03A Manual Transaxle Transmission T5OD 2003 Mustang Workshop Manual Special Tool s Pinion Bearing Cone Remove 205 D002 D79L 4621 A or Equivalent Spiral Snap Ring Replacer 308 096 T85P 7025 A ...

Page 2727: ...th speed driven gear 7K316 5 Remove the output shaft rear bearing 7065 6 Remove the first gear 7100 7 NOTE The first gear bearing spacer 7173 fits snugly on the output shaft assembly 7061 Remove the first gear bearing 7127 and the spacer as an assembly ...

Page 2728: ...hronizer inner cone 7175 the first speed synchronizer outer cone 7174 and the first speed synchronizer blocking ring 7107 as an assembly 10 Remove the snap ring and the thrust washer 7119 11 Remove the second gear 7102 the second speed bearing 7B369 and the second speed gear bearing spacer 7728 ...

Page 2729: ... gear synchronizer sliding sleeve 7124 15 CAUTION Note the orientation of the synchronizer hub insert springs 7109 and the synchronizer hub inserts 7A044 for assembly reference NOTE The first and second gear synchronizer sliding sleeve the hub and the output shaft are an assembly Do not attempt to separate the hub from the output shaft Only the synchronizer hub insert springs and the synchronizer ...

Page 2730: ...he sliding sleeve onto the hub 3 NOTE If not done so previously soak the blocking ring in MERCON Multi Purpose ATF Transmission Fluid XT 2 QDX or equivalent for ten minutes NOTE Align the slots in the synchronizer blocking ring with the tabs in the first and second speed synchronizer Install the second speed synchronizer blocking ring and the inner and outer cones as an assembly 4 Install the seco...

Page 2731: ...in the second gear with the tabs on the synchronizer blocking ring Install the second gear onto the output shaft 8 Install the thrust washer and the snap ring 9 NOTE If not done so previously soak the blocking ring in MERCON Multi Purpose ATF Transmission Fluid XT 2 QDX or equivalent for ten minutes ...

Page 2732: ... outer cones as an assembly 10 Install the first and second speed synchronizer hub ball 11 NOTE Align the notch in the first gear bearing spacer with the first and second speed synchronizer ball Install the first gear bearing spacer and the first gear bearing 12 NOTE Align the slots on the synchronizer blocking ring with the slots on the first gear Install the first gear ...

Page 2733: ... CAUTION Align the output shaft splines and the splines of the fifth speed driven gear or damage will occur Position the fifth speed driven gear on the output shaft Using a press and a capped length of pipe 31 7 mm 1 26 in inside diameter X 356 mm 14 24 in long install the fifth speed driven gear 16 Install the snap ring ...

Page 2734: ... Hold the third gear against the synchronizer to maintain the synchronizer blocking ring alignment NOTE If not done so previously soak the blocking ring in MERCON Multi Purpose ATF Transmission Fluid XT 2 QDX or equivalent for ten minutes Using a 1 1 2 inch deep well socket and a press install the third gear the third speed synchronizer blocking ring and the third fourth gear synchronizer assembly...

Page 2735: ......

Page 2736: ...l Special Tool s Bearing Replacer 308 061 T77J 7025 L Front Bearing Replacer 308 062 T77J 7025 M Mainshaft Front Bearing Replacer 308 081 T82T 7003 DH Pinion Bearing Cone Remover 205 D002 D79L 4621 A or Equivalent Pinion Bearing Cone Replacer 205 011 T57L 4621 B Remover and Replacer Tube 308 024 T75L 7025 B Remover and Replacer Tube 308 052 T77J 7025 B ...

Page 2737: ...only if damaged or worn Using the special tools and a press remove the bearing race and the countershaft front bearing seal 7693 Assembly NOTE Position the countershaft in the transmission case before installing the rear countershaft bearing 1 Install the countershaft front bearing seal on the bearing race 2 Coat the outside diameter of the bearing race with sealer Use Threadlock and Sealer E0AZ 1...

Page 2738: ...upport the case during bearing race installation will result in permanent distortion of the case Using the special tools and a press install the bearing race 4 Using the special tool and a press install the front countershaft bearing ...

Page 2739: ...hub insert springs 3 The first second speed synchronizer sliding sleeve the hub and the output shaft are an assembly Do not attempt to separate the hub from the output shaft Discard the entire assembly if wear or damage to the synchronizer or output shaft is evident 4 On the third fourth speed synchronizer and the fifth speed synchronizer remove the sliding sleeve Assembly 1 NOTE Both synchronizer...

Page 2740: ...arks made during disassembly The sleeve and the hub have an extremely close fit Hold the sleeve and hub square to prevent jamming Do not force the sleeve onto the hub On the third fourth speed synchronizer and the fifth speed synchronizer install the sliding sleeve ...

Page 2741: ...r Equivalent Gauge Clutch Housing 308 021 T75L 4201 A Extension Housing Seal Replacer 308 227 T94P 7657 A Holding Fixture 307 003 T57L 500 B Remover and Replacer Tube 308 052 T77J 7025 B Torrington Bearing Installer 308 083 T83P 7025 AH Material Item Specification Motorcraft MERCON Multi Purpose ATF Transmission Fluid XT 2 QDX MERCON Pipe Sealant with Teflon ESR M18P7 ...

Page 2742: ...the case Using a the special tools and a press install the rear countershaft bearing assembly 1 Position two 6 35 mm 0 25 in pieces of bar stock between the countershaft and the case 2 Using a the special tools and a press install the rear countershaft bearing assembly D8AZ 19554 A A Multi Purpose Grease D0AZ 19554 AA ESB M1C93 B Clear Silicone Rubber D6AZ 19562 AA ESB M4G92 A Motorcraft Premium L...

Page 2743: ...emove the countershaft rear bearing retainer and install the necessary thickness shim s Reinstall the countershaft rear bearing retainer and recheck the end play Bend the tabs of the countershaft rear bearing retainer over the bolts when the end play adjustment is complete 7 Position the reverse idler gear and bushing in the case with the shift lever groove facing the rear of the case Install the ...

Page 2744: ...g spring rotation The spring must rotate counterclockwise into its installed position Install the reverse shift fork Place the reverse idler gear and bushing into the NEUTRAL position Align the reverse shift fork and the reverse idler gear and bushing Push downward on the reverse shift fork until fully engaged into the reverse idler gear and bushing ...

Page 2745: ...g around the shift lever reverse pin Apply pipe sealant to the shift lever reverse pin threads and install the pin 13 Install the roller bearings the input shaft bearing spacer the thrust bearing and the thrust washer Coat the 15 bearings the spacer the thrust bearing and the thrust washer with grease ...

Page 2746: ...zer hub inserts 15 NOTE Verify that the fourth speed synchronizer blocking ring is still in position Align the flat on the fourth gear clutching teeth with the countershaft cluster gear and install the input shaft 16 NOTE Do not install the end play shims at this time NOTE Do not apply sealant to the input shaft bearing retainer at this time Install the bearing race in the bearing retainer 17 Inst...

Page 2747: ...th the slot in the case and align the reverse gear shift rail with the reverse shift fork Once the ball stud enters the case rotate the reverse gear shift rail until the ball aligns with the reverse gearshift lever Rotate the reverse gear shift rail counterclockwise until the ball stud fully engages the reverse gearshift lever ...

Page 2748: ...he extension housing 7A039 the alignment tab on the reverse brake ring 7M000 must engage the alignment slot in the extension housing NOTE If not done so previously soak the blocking ring in transmission fluid for ten minutes Install the synchronizer blocking ring the reverse brake ring the thrust washer and the fifth speed synchronizer retaining snap ring 23 Apply pipe sealant to the reversing lam...

Page 2749: ... silicone rubber to the sealing surface on the case cover 27 NOTE Verify that all of the synchronizers are in the NEUTRAL position and the gear shifter forks in the cover are in the NEUTRAL position Install the case cover Position the cover toward the filler plug side of the transmission and lower it until the gear shifter forks engage the synchronizers Continue to lower the cover and move it into...

Page 2750: ...Position the gearshift offset lever in the extension housing with the gear shift interlock spring over the detent ball 31 CAUTION To prevent component damage the alignment tab on the reverse brake ring must align with the alignment slot in the extension housing NOTE Verify that the oil pick up funnel engages the fifth gear synchronizer Slide the gearshift offset lever and the extension housing int...

Page 2751: ...all the split pin and the gearshift shaft bushing 34 Using the special tools measure the output shaft end play 1 Place the transmission in a vertical position 2 Install the special tool 3 Push upward on the input shaft and record the dial indicator reading ...

Page 2752: ...shim with a thickness equal to the dial indicator reading This will provide zero end play Rotate the transmission to the horizontal position and remove the input shaft bearing retainer Remove the bearing race and install the necessary shim s 36 CAUTION Do not cover the notch in the input shaft bearing retainer with sealer Apply a 3 2 mm 1 8 inch bead of silicone rubber to the sealing surface on th...

Page 2753: ...special tool install the extension housing fluid seal 41 Install the case plug 42 NOTE Before installing the transmission the ball stud clutch release lever and the input shaft must be cleaned and lubricated with grease Install the clutch release hub and bearing and the clutch release lever For additional information refer to Section 308 01 ...

Page 2754: ......

Page 2755: ...rease XG 1 C or XG 1 K or equivalent meeting Ford specification ESA M1C75 B To install reverse the removal procedure Refer to Transmission in this section Check and as necessary fill the transmission with MERCON Multi Purpose ATF Transmission Fluid XT 2 QDX or equivalent The total fill capacity is 2 6L 2 8 qt SECTION 308 03A Manual Transaxle Transmission T5OD 2003 Mustang Workshop Manual ...

Page 2756: ...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 ...

Page 2757: ...Crossmember to transmission support bolt 58 43 Driveshaft flange to pinion flange bolt 112 83 ...

Page 2758: ... and helical cut The reverse gear operates through a constant mesh fully synchronized system The shift interlock system prevents the engagement of more than one gear The countershaft is serviced as an assembly An aluminum main case extension housing and bell housing Transmission Internal Components Disassembled View SECTION 308 03B Manual Transaxle Transmission TR3650 2003 Mustang Workshop Manual ...

Page 2759: ...rt Number Description 1 7052 Input shaft seal 2 7L172 Shim 3 7025 Input shaft front bearing and cup 4 7017 Input shaft 5 7025 Input shaft pocket bearing 6 Input shaft thrust bearing 7 Input shaft thrust washer ...

Page 2760: ...tput shaft 25 Retaining ring 26 7124 First second gear synchronizer assembly 27 7107 First second gear synchronizer blocking ring 28 First second gear synchronizer spring part of 7124 29 First second gear synchronizer hub part of 7124 30 First second gear synchronizer insert part of 7124 31 First second gear synchronizer sleeve part of 7124 32 7127 First gear needle bearing 33 7100 First gear 34 R...

Page 2761: ... 57 Countershaft fifth gear needle bearing 58 Countershaft fifth gear bearing spacer 59 Retaining ring 60 7124 Fifth gear synchronizer assembly 61 7107 Fifth gear synchronizer blocking ring 62 Fifth gear synchronizer spring part of 7124 63 Fifth gear synchronizer hub part of 7124 64 Fifth gear synchronizer insert part of 7124 65 Fifth gear synchronizer sleeve part of 7124 66 Fifth gear clutch cone...

Page 2762: ...4 First second shift finger 5 7241 Third fourth shift rail 6 7230 Third fourth shift fork 7 7L082 Shift fork inserts 8 Third fourth shift finger 9 7242 Fifth reverse shift rail 10 Reverse gear shift fork 11 Fifth gear shift fork 12 7L082 Shift fork inserts 13 Shift arm bearing 14 Spacer 15 Shift arm selector inhibitor ...

Page 2763: ...offset lever 18 Spacer 19 Bearing 20 7210 Gearshift lever 21 Gearshift plate and spring 22 Shipping seal 23 7052 Output shaft seal 24 Extension housing bushing 25 7A039 Extension housing 26 7034 Vent 27 Vehicle speed sensor VSS 28 Fifth reverse gear lockout 29 7L027 Magnet 30 7K201 Shift interlock plate 31 7005 Transmission main case 32 Interlock pins 33 7A010 Drain plug 34 15520 Reverse lamp swit...

Page 2764: ... 1 Transmission assembly number 2 Build date code month 3 Build date code day 4 Build date code year 5 Shift number 6 Serial number 7 Service repair code 8 Identification number located on left lower side of transmission case ...

Page 2765: ...DIAGNOSIS AND TESTING Manual Transmission Refer to Section 308 00 SECTION 308 03B Manual Transaxle Transmission TR3650 2003 Mustang Workshop Manual ...

Page 2766: ...galling metal smears on roller ends Galling is caused by overheating poor lubrication or an overload situation If galling is found install a new bearing and inspect the seals 3 Inspect the bearing for brinelling surface indentations in the raceway 4 Inspect bearing for cracked inner race SECTION 308 03B Manual Transaxle Transmission TR3650 2003 Mustang Workshop Manual ...

Page 2767: ...seals 6 Inspect the bearing for heat discoloration dark blue If heat discoloration is evident check the bearing and race for loss of temper Draw a file across the component If the file cuts the metal there is a loss of temper 7 Inspect the bearing for fatigue spalling metal flaking ...

Page 2768: ......

Page 2769: ...move the driveshaft For additional information refer to Section 205 01 3 Using the special tools remove the extension housing fluid seal Installation 1 Using the special tool install the extension housing fluid seal SECTION 308 03B Manual Transaxle Transmission TR3650 2003 Mustang Workshop Manual Special Tool s Installer Transmission Extension Housing Oil Seal 308 227 T94P 7657 A Slide Hammer 100 ...

Page 2770: ...2 CAUTION Align the index marks Install the driveshaft For additional information refer to Section 205 01 3 Check the transmission fluid level add fluid if necessary 4 Lower the vehicle ...

Page 2771: ...Remove the console panel gearshift plate Lift the gearshift lever boot over the gearshift lever 3 Remove the bolts and the shift lever SECTION 308 03B Manual Transaxle Transmission TR3650 2003 Mustang Workshop Manual Material Item Specification Clear Silicone Rubber D6AZ 19562 AA or equivalent ESB M4G92 A ...

Page 2772: ... 6 Remove the gearshift lever boot 7 CAUTION Cover the opening in the extension housing to prevent contamination Clean the gearshift lever mounting surfaces 8 To install reverse the removal procedure Apply a 3 2 mm 1 8 in bead of silicone rubber to the sealing surface on the gearshift lever ...

Page 2773: ......

Page 2774: ... NEUTRAL raise and support the vehicle For additional information refer to Section 100 02 2 Disconnect the electrical connector 3 Remove the output shaft speed OSS sensor 4 To install reverse the removal procedure SECTION 308 03B Manual Transaxle Transmission TR3650 2003 Mustang Workshop Manual ...

Page 2775: ......

Page 2776: ...er 4 Remove the bolts and the shift lever 5 With the vehicle in NEUTRAL raise and support the vehicle For additional information refer to Section 100 02 6 Remove the dual converter H pipe For additional information refer to Section 309 00 7 CAUTION Index mark the driveshaft flange and pinion flange and the driveshaft slip yoke and transmission output shaft SECTION 308 03B Manual Transaxle Transmis...

Page 2777: ...8 Disconnect the reversing lamp switch electrical connector Disconnect the wiring harness from the transmission 9 Remove the starter motor For additional information refer to Section 303 06 10 Remove the bolts 11 Remove the starter solenoid nuts and position the wires aside ...

Page 2778: ... transmission 14 Remove the bolt and the clutch release lever cover 15 CAUTION To prevent component damage do not depress the clutch pedal with the transmission removed Disengage the clutch release cable from the clutch release fork 16 Remove the clutch cable retainer and remove the clutch cable from the transmission ...

Page 2779: ... If transmission disassembly is necessary drain the transmission fluid 18 Position a transmission jack and support the transmission 19 Remove the bolts and the transmission crossmember 20 Remove the bolts ...

Page 2780: ...21 Lower the transmission and remove the five bolts ...

Page 2781: ... wear is in place Clean the transmission exterior with solvent and dry with compressed air During disassembly clean all components with solvent and dry with compressed air 3 Attach the transmission to the special tool SECTION 308 03B Manual Transaxle Transmission TR3650 2003 Mustang Workshop Manual Special Tool s Remover Mainshaft Bearing 308 058 T77J 7025 H Screw Bearing Removal tube 308 092 T84T...

Page 2782: ...ission Remove the case plug then rotate the transmission to a horizontal position 5 Using the special tools remove the extension housing fluid seal 6 NOTE Rotate the transmission to a vertical position NOTE Position the gearshift lever in NEUTRAL ...

Page 2783: ...t offset lever insert and O ring for wear or damage Install a new insert as necessary 8 NOTE If necessary remove the spring and plate for disassembly Remove the bolts and the shift spring and plate 9 Using a 5 32 inch drift and a hammer drive the split pin downward ...

Page 2784: ...parate the extension housing then remove the gearshift offset lever from the transmission case Remove and discard the split pin from the gearshift offset lever during removal 12 Remove the fifth reverse gear lockout bolt 13 Remove the fifth reverse gear lockout ...

Page 2785: ...14 Remove the shipping seal 15 Remove the OSS sensor tone wheel retaining ring 16 Using the special tools remove the OSS sensor tone wheel 17 Remove the OSS sensor tone wheel check ball ...

Page 2786: ...ining ring 19 Using a 5 32 inch drift and a hammer remove and discard the pin from the fifth gear shift fork 20 Remove the fifth gear shift fork synchronizer assembly synchronizer cone and the fifth gear as an assembly 21 Remove the fifth gear clutch cone ...

Page 2787: ...age Install new blocking rings as necessary 23 Remove the fifth gear synchronizer sleeve from the synchronizer hub 24 Remove the synchronizer inserts and the springs 25 Remove the needle bearings and the thrust washer The fifth gear needle bearing is three separate pieces bearing spacer bearing ...

Page 2788: ... 26 Remove the check ball 27 Using a 5 32 inch drift and a hammer drive out the split pin then remove the third fourth shift finger Discard the split pin 28 Using a 5 32 inch drift and a hammer drive out the split pin then remove the first second shift finger Discard the split pin ...

Page 2789: ...l and the plastic spacer 30 Remove the bolts and the shift interlock plate 31 Using a magnet remove the interlock pins One lock pin in the center rail two between the rails 32 Remove the three detent plugs springs and the detents ...

Page 2790: ...he transmission to a horizontal position Remove 12 bolts leaving two opposing bolts in Rotate the transmission to a vertical position then remove the remaining two bolts 34 Carefully pry the clutch housing from the transmission main case 35 Remove the transmission main case from the clutch housing ...

Page 2791: ...36 Lift the mainshaft 13 mm 0 50 in upward tilt the countershaft outward and remove the countershaft 37 Remove the mainshaft and shift assembly ...

Page 2792: ... to Input Shaft and Bearing in this section 39 Remove the shift rails and shift forks from the main shaft For gearshift rail and fork disassembly refer to Gearshift Rail and Fork in this section 40 Remove the reverse idler shaft bolt Remove and discard the seal ...

Page 2793: ...reverse idler gear bearing The reverse idler gear is three separate pieces bearing spacer bearing Inspect the bearing for wear or damage Install new bearings as necessary 44 Disassemble the clutch housing 1 Remove the countershaft bearing cup and shim 2 Remove the input shaft bearing cup and shim 3 Remove the input shaft seal Carefully pry out from the inside of the case ...

Page 2794: ...45 Remove the rear countershaft bearing 46 Remove the rear countershaft bearing cup and the rear output shaft bearing cup ...

Page 2795: ......

Page 2796: ... the input shaft thrust bearing 4 Remove the input shaft pocket bearing Inspect all components for wear or damage Install new components as necessary SECTION 308 03B Manual Transaxle Transmission TR3650 2003 Mustang Workshop Manual Special Tool s Remover Driver Pinion Bearing Cone 205 D002 D79L 4621 A or equivalent Installer Drive Pinion Bearing Cone 205 011 T57L 4621 B Remover Installer Bearing T...

Page 2797: ...t and bearings for wear or damage Install new components as necessary 4 Using the special tools and a press install the new input shaft front bearing 5 Install the input shaft pocket bearing the washer input shaft bearing and the third fourth synchronizer blocking ring Lubricate the bearing and bearing race with petroleum jelly ...

Page 2798: ......

Page 2799: ... the press to prevent damage to the shaft or gears Using the special tool press fifth gear the spacer the output shaft bearing and reverse gear from the output shaft Discard the output shaft bearing SECTION 308 03B Manual Transaxle Transmission TR3650 2003 Mustang Workshop Manual Special Tool s Remover Drive Pinion Bearing Cone 205 D002 D79L 4621 A or equivalent Installer Drive Pinion Bearing Cone...

Page 2800: ...ng for wear or damage Install a new needle bearing as necessary 4 Remove the check ball and the blocking ring Inspect the blocking ring for wear or damage Install new blocking rings as necessary 5 NOTE Install the special tool with the flat side facing first gear ...

Page 2801: ...e the first gear needle bearing Inspect the needle bearing for wear or damage Install a new needle bearing as necessary 7 Remove the first gear synchronizer inner cone the first gear synchronizer outer cone and the first gear synchronizer blocking ring Inspect all components for wear or damage Install new components as necessary ...

Page 2802: ...th the input shaft end facing upward Remove and discard the retaining ring 9 Remove the third fourth synchronizer hub 10 Remove the third fourth blocking ring 11 Remove the third gear Inspect the gear for wear or damage Install a new gear as necessary ...

Page 2803: ...cer second gear thrust washer and second gear Inspect the gear for wear or damage Install a new gear as necessary 14 Remove the check ball and second gear needle bearing Inspect the needle bearing for wear or damage Install a new needle bearing as necessary 15 Remove the second gear synchronizer inner cone second gear synchronizer outer cone and the second gear synchronizer blocking ring Inspect a...

Page 2804: ... for wear or damage Inspect the output shaft for scoring or worn or damaged splines Install new components as necessary 2 Lubricate all components with the recommended transmission fluid when reassembling 3 NOTE Position the output shaft with the output end facing upward NOTE Install the synchronizer assembly with the deeper center flange of the synchronizer hub facing toward the rear of the outpu...

Page 2805: ... synchronizer blocking ring Align the blocking ring tabs with the synchronizer assembly 5 Install the outer first gear synchronizer cone 6 Install the inner first gear synchronizer cone Rotate the inner cone till it is seated ...

Page 2806: ...7 Install the first gear needle bearing Apply petroleum jelly to the bearing 8 Install first gear Rotate the gear to align the gear slots with the inner cone tabs 9 Install the reverse synchronizer cone ...

Page 2807: ...10 Install the reverse gear blocking ring 11 Using the special tools install the reverse gear bearing spacer 12 Install reverse gear needle bearing Apply petroleum jelly to the bearing ...

Page 2808: ...ate the gear to align the gear slots with the inner cone tabs 14 Install the check ball Use petroleum jelly to hold the check ball in place 15 Install the thrust washer Be sure to align the slot in the washer with the check ball ...

Page 2809: ... and gear into place 17 Reposition the output shaft with the input end facing upward 18 Install the second gear synchronizer blocking ring Rotate the blocking ring until seated 19 Install the second gear synchronizer outer cone and the second gear synchronizer inner cone 20 Install the second gear bearing ...

Page 2810: ...Apply petroleum jelly to the bearing 21 Install second gear Rotate the gear to align the gear slots with the inner cone tabs 22 Install the check ball Use petroleum jelly to hold the check ball in place ...

Page 2811: ...23 Install the thrust washer Be sure to align the slot in the washer with the check ball 24 Press the bearing spacer onto the output shaft ...

Page 2812: ...25 Install the third gear bearing Apply petroleum jelly to the bearing 26 Install third gear ...

Page 2813: ...nstall the third gear synchronizer blocking ring 28 Install the third fourth gear synchronizer body Install the synchronizer body with the raised center facing downward Rotate the blocking ring until seated ...

Page 2814: ...29 Install a new retaining ring ...

Page 2815: ......

Page 2816: ...s 2 Using the special tool and a press remove the inner bearing 3 Using the special tools install the new countershaft bearing SECTION 308 03B Manual Transaxle Transmission TR3650 2003 Mustang Workshop Manual Special Tool s Remover Drive Pinion Bearing Cone 205 D002 D79L 4621 A or equivalent Installer Drive Pinion Bearing Cone 205 011 T57L 4621 B ...

Page 2817: ......

Page 2818: ...ove the sliding sleeve then remove the synchronizer struts and the springs 3 Install the synchronizer struts and the springs 4 CAUTION Match the alignment marks made during disassembly The sleeve and the hub have an extremely close fit Hold the sleeve and hub square to prevent jamming Do not force the sleeve onto the hub Install the sliding sleeve SECTION 308 03B Manual Transaxle Transmission TR36...

Page 2819: ......

Page 2820: ...ring from the transmission case Discard the bearing 2 Using the special tool install the main shift rail bearing SECTION 308 03B Manual Transaxle Transmission TR3650 2003 Mustang Workshop Manual Special Tool s Universal Puller Set 303 DS005 D80L 100 A or equivalent Installer Shift Rail Bushing 308 244 T96P 7025 F Slide Hammer 100 001 T50T 100 A ...

Page 2821: ......

Page 2822: ...in Slide the shift fork from the shift rail 2 Remove the gearshift fork inserts 3 CAUTION Support the shift rail to prevent damage to the parts Position the gearshift fork on the shift rail Align the split pin hole and install a new split pin 4 Install the gear shift fork inserts SECTION 308 03B Manual Transaxle Transmission TR3650 2003 Mustang Workshop Manual ...

Page 2823: ......

Page 2824: ...s Dial Indicator Gauge with Holding Fixture 100 002 TOOL 4201 C or equivalent Holding Fixture Transmission 307 003 T57L 500 B Remover Installer Bearing Tube 308 024 T75L 7025 B Replacer Adapter 308 239 T96P 7025 A Installer Transmission Extension Housing Oil Seal 308 227 T94P 7657 A Material Item Specification Motorcraft MERCON Multi Purpose ATF Transmission Fluid XT 2 QDX MERCON Premium Long Life...

Page 2825: ...being used install new bearing cups Install the rear countershaft bearing cup and the rear output shaft bearing cup Lubricate the bearing cups and the shift rail bearing with petroleum jelly 4 Install the rear countershaft bearing 5 Install the reverse idler gear bearings and spacer on the shaft ...

Page 2826: ...rse idler bolt then install the bolt in the transmission case 9 NOTE If a new front input shaft bearing or front countershaft bearing was installed install new bearing cups Install the front input shaft bearing cup and the front countershaft bearing cup Do not install the shims at this time Install the transmission main case ...

Page 2827: ...he input shaft 11 Install the shift rails and shift forks on the mainshaft 12 Install the mainshaft onto the clutch housing The notches on the shift rail should be pointing upward Align the shift rails in the bores ...

Page 2828: ...aft and install 14 Install the case with two opposing bolts 15 NOTE Rotate the transmission so that the input shaft is pointing upward NOTE Rotate the input shaft to seat the bearings Using the special tools measure the input shaft end play by applying an upward load on the ...

Page 2829: ...e input shaft is pointing downward 17 NOTE Rotate the countershaft to seat the bearings Using the special tools measure the countershaft gear end play by pulling upward on the countershaft Record the measurement 18 Remove the two bolts and lift the transmission main case off ...

Page 2830: ...19 Remove the countershaft 20 Remove the mainshaft ...

Page 2831: ...21 Remove the input shaft 22 Remove the front input shaft bearing cup and the front countershaft bearing cup 23 Using the special tools install the new input shaft seal ...

Page 2832: ... play measurements select and install the appropriate shims to achieve the correct end play 25 Install the front input shaft bearing cup and the front countershaft bearing cup 26 Install the input shaft 27 Install the mainshaft ...

Page 2833: ... Clean the mating surfaces of the transmission main case and the clutch housing Apply a bead of silicone rubber to the sealing surface on the clutch housing then install the transmission main case Tighten the bolts in a star pattern ...

Page 2834: ...30 Install the lock pins 31 Install the lock plate ...

Page 2835: ...he detents and the detent springs 33 Install the detent plugs 34 Install the check ball Use petroleum jelly to hold the check ball in place 35 Install the thrust washer and the three piece fifth gear needle bearing ...

Page 2836: ...ve on the synchronizer hub Align the pockets in the blocking ring with the struts in the synchronizer The sliding sleeve is not reversible Install the sleeve with the bevel edge away from the gear 38 Install fifth gear blocking ring 39 Install the fifth gear synchronizer cone ...

Page 2837: ...onizer cone and fifth gear as an assembly 41 Install a new split pin Install the pin until it is flush with the fork 42 Install a new snap ring 43 Install the third fourth shift finger then install a new split pin Install the split pin until it is flush with the shift finger ...

Page 2838: ...all the split pin until it is flush with the shift finger 45 Install the OSS sensor tone wheel check ball Use petroleum jelly to hold the check ball in place 46 Place the OSS sensor tone wheel on the output shaft aligning the slot in the OSS wheel with the check ball Using the special tool install the OSS sensor tone wheel ...

Page 2839: ...ar lockout 49 Install the bolt 50 Clean the mating surfaces of the transmission main case and the extension housing Apply a bead of silicone rubber to the sealing surface of the transmission case 51 Install the extension housing and at the same time install the gear shift off set lever ...

Page 2840: ...ever The split pin should be flush in the gear shift off set lever 54 Seat the extension housing and tighten the bolts to specification Fill the gear shift off set lever with petroleum jelly 55 Using the special tool install a new extension housing seal Lubricate the seal with transmission fluid ...

Page 2841: ...n 58 Clean the mating surfaces of the shift cover opening surface and the shift cover Apply a bead of silicone rubber to the shift cover opening surface 59 Install the gear shift lever 60 NOTE Before installing the transmission the ball stud the clutch release lever and the input ...

Page 2842: ...ated Install the clutch release hub and bearing and the clutch release lever For additional information refer to Section 308 01 61 Fill the transmission with transmission fluid to the specified level Transmission capacity is 3 6 liters 7 5 pints ...

Page 2843: ...ransmission in this section Check and as necessary fill the transmission with transmission fluid The total fill capacity is 3 6L 7 5 pt 2 Apply sealant to the fill plug threads and install the fill plug Use pipe sealant with Teflon SECTION 308 03B Manual Transaxle Transmission TR3650 2003 Mustang Workshop Manual Material Item Specification Motorcraft MERCON Multi Purpose ATF Transmission Fluid XT ...

Page 2844: ... 0 002 in Countershaft extension preload 0 05 mm in 0 13 mm 0 005 in Fluid DEXRON III ATF Transmission Fluid XT 2 QDX DEXRON III Capacity 3 9 L 4 1 qt Synchronizer Synchronizer blocking ring to conical face runout 1st 2nd 3rd 4th 5th 6th gear 0 38 mm 0 01 in Synchronizer blocking ring to conical face runout Reverse gear 0 75 mm 0 03 in Torque Specifications Description Nm lb ft lb in Transmission ...

Page 2845: ...16 Reverse lockout solenoid bolt 18 13 Drain plug 27 20 Reversing lamp switch 27 20 Fill plug 27 20 Reverse idler shaft bracket bolts 25 18 Extension housing bolts 35 26 Shift dent cover bolts 20 15 Adapter plate plug 27 20 ...

Page 2846: ...g on the input shaft a tapered roller bearing on the countershaft extension countershaft cluster endplay controlled by shims located in the transmission adapter plate countershaft extension endplay controlled by shims located in the extension housing input output shaft endplay is controlled by shims located in the transmission adapter plate removable wear pads on the shift forks an aluminum main c...

Page 2847: ...3 Build date code day 4 Build date code year 5 Shift number 6 Serial number 7 Service repair code 8 Identification number located on left lower side of transmission case ...

Page 2848: ...DIAGNOSIS AND TESTING Manual Transmission Refer to Section 308 00 SECTION 308 03C Manual Transaxle Transmission T56 2003 Mustang Workshop Manual ...

Page 2849: ...3 NOTE Before removing clean the area around the filler plug Remove the filler plug 4 Using a suitable oil suction gun fill the transmission to the correct level with the specified fluid Transmission capacity is 3 9 liters 4 1 quarts SECTION 308 03C Manual Transaxle Transmission T56 2003 Mustang Workshop Manual Material Item Specification DEXRON III ATF Transmission Fluid XT 2 QDX DEXRON III ...

Page 2850: ...5 Install the filler plug ...

Page 2851: ...ate Disconnect the cigar lighter electrical connector then lift the gearshift lever boot over the gearshift lever 3 Remove the bolts and the upper gearshift lever 4 Remove the bolts and the lower gearshift lever boot SECTION 308 03C Manual Transaxle Transmission T56 2003 Mustang Workshop Manual ...

Page 2852: ...reverse lockout solenoid electrical connector 7 With the vehicle in NEUTRAL raise and support the vehicle For additional information refer to Section 100 02 8 Drain the transmission fluid 9 CAUTION Index mark the driveshaft flange and pinion flange and the driveshaft ...

Page 2853: ...ation refer to Section 205 01 10 Disconnect the heated oxygen sensor HO2S electrical connectors from the crossmember 11 Position a transmission jack and support the transmission 12 Remove the bolts and the transmission crossmember 13 Remove the bolt and the clutch release lever cover ...

Page 2854: ...tch release cable from the clutch release fork 15 Disconnect the wiring harness from the transmission 16 Disconnect the output shaft speed OSS sensor electrical connector 17 Disconnect the reverse lamp electrical connector ...

Page 2855: ...ch adapter housing bolts 19 Move the transmission rearward until the input shaft is clear of the pressure plate then lower the rear of the transmission while moving it forward to clear the exhaust pipe Lower the transmission from the vehicle ...

Page 2856: ...ake sure protective eye wear is in place SECTION 308 03C Manual Transaxle Transmission T56 2003 Mustang Workshop Manual Special Tool s Holding Fixture Transmission 307 003 T57L 500 B Puller Bearing 205 D064 D84L 1123 A 2 or 3 Jaw Puller 205 D027 D80L 1013 A Remover Mainshaft Bearing 308 058 T77J 7025 H Remover Installer Bearing Tube 308 025 T75L 7025 C Removal Screw Bearing Tube 308 092 T84T 7025 ...

Page 2857: ...ith compressed air 2 Remove the clutch release hub and bearing and the clutch release lever 3 Attach the transmission to the special tool 4 Rotate the transmission to a horizontal position 5 NOTE Position a drain pan under the transmission If the transmission was not drained during removal drain the transmission 6 Remove the vent hose ...

Page 2858: ... drift and a hammer drive the roll pin downward then remove the rear offset shift lever Inspect the rear offset shift lever for wear or damage Install a new lever as necessary Discard the roll pin 8 Remove the eight bolts and carefully separate the extension housing from the transmission ...

Page 2859: ...smission adapter plate 10 NOTE Rotate the transmission to a vertical position Remove the shipping seal 11 Remove the output shaft speed OSS sensor tone wheel retaining ring 12 Using the special tools remove the OSS sensor tone wheel ...

Page 2860: ...nd discard the rear mainshaft roller bearing snap ring 15 Remove the upper spacer the rear mainshaft roller bearing and the lower spacer Inspect the rear mainshaft roller bearing for wear or damage Install a new bearing as necessary 16 Remove and discard the reverse gear snap ring ...

Page 2861: ...verse gear for wear or damage Install a new gear as necessary 19 Remove the wave washer from the reverse gear 20 Remove the reverse gear needle bearing and the reverse gear synchronizer blocking ring Inspect the needle bearing for wear or damage Install a new bearing as necessary ...

Page 2862: ...cessary 25 Inspect the synchronizer blocking ring for the following Check for wear or damage Install a new synchronizer blocking ring as necessary Check the clearance between the synchronizer blocking ring and the gear Position the blocking ring onto the gear Make sure the correct blocking ring is measured with the correct gear and that the blocking ring is fully seated on the gear Insert a feeler...

Page 2863: ...ial tools remove the fifth sixth driven gear 27 Remove the fifth sixth shift fork snap ring 28 Rotate the transmission to the horizontal position then remove the countershaft extension as an assembly 29 Remove the shift detent cover ...

Page 2864: ...nt assembly 31 Using a 5 32 inch drift and a hammer drive the roll pin downward 32 Remove nine of the adapter to transmission case bolts 33 NOTE Rotate the transmission to a vertical position Remove the shift lever guide bolts ...

Page 2865: ... upward off the mainshaft and shift rails Hold the offset lever against the guide plate to prevent the release of the dent ball and spring 35 Remove the dent ball spring and roll pin from the front offset lever 36 Rotate the fifth sixth and reverse shift levers from the shift interlock plate then remove the fifth sixth and reverse shift rail assembly ...

Page 2866: ...the mainshaft on the work bench 39 Remove the input shaft and fourth gear synchronizer blocking ring 40 Remove the countershaft bearing cup and the countershaft shim Inspect the cup for wear or damage Install a new cup and bearing as necessary Inspect the cup bore for wear scratches or grooves Install a new transmission adapter plate as necessary ...

Page 2867: ...ate as necessary 42 Remove and discard the input shaft seal 43 WARNING Make sure protective eye wear is in place Clean the transmission adapter plate with solvent and dry with compressed air Inspect the adapter plate for cracks Clean and check the sealing surface for nicks or scratches If the adapter plate is cracked install a new plate If the sealing surface has nicks or scratches use a soft ston...

Page 2868: ......

Page 2869: ... 03C Manual Transaxle Transmission T56 2003 Mustang Workshop Manual Special Tool s Plate Bearing Oil Seal 205 090 T75L 1165 B Puller Bearing 205 D064 D84L 1123 A Installer Drive Pinion Bearing Cone 205 004 T53T 4621 B Adapter Set Step Plate 205 DS011 D80L 630 A Universal Puller Set 303 DS005 D80L 100 A ...

Page 2870: ...d a slide hammer remove the input shaft bearing cup Inspect the cup for wear or damage Install a new bearing cup and bearing as necessary 2 Using the special tool and a press remove the input shaft front bearing Item Part Number Description 1 7025 Input shaft bearing 2 7017 Input shaft 3 Input shaft bearing cup ...

Page 2871: ... new components as necessary 4 Using the special tools and a press install a new input shaft bearing Lubricate the bearing with petroleum jelly 5 Using a suitable driver and the press install the input shaft bearing cup Lubricate the bearing cup with petroleum jelly ...

Page 2872: ......

Page 2873: ...Transmission T56 2003 Mustang Workshop Manual Special Tool s Puller Bearing 205 D064 D84L 1123 A Adapter for 303 224 Handle 205 153 T80T 4000 W Installer Output Shaft Rear Bearing 308 401 Remover Installer Bearing Tube 308 025 T75L 7025 C Item Part Number Description 1 7025 Output shaft front bearing ...

Page 2874: ...ge Install a new gear as necessary 2 Snap ring 3 7124 Third fourth synchronizer assembly 4 7107 Third fourth synchronizer blocking ring 5 7B340 Third gear 6 Spacer 7 Third gear needle bearing 8 7061 Output shaft 9 Second gear needle bearing 10 7102 Second gear 11 Thrust washer 12 Synchronizer inner cone 13 Synchronizer friction cone 14 7107 Second gear synchronizer blocking ring 15 7124 First seco...

Page 2875: ... Install a new needle bearing as necessary 3 Remove and discard the snap ring 4 Remove the first gear synchronizer thrust washer the inner cone the friction cone and the first gear synchronizer blocking ring Inspect all components for wear or damage Install new components as necessary ...

Page 2876: ...ond gear Using the special tool remove the second gear the second gear synchronizer thrust washer the inner cone the friction cone the second gear synchronizer blocking ring and the synchronizer hub Inspect the gear for wear or damage Install a new gear as necessary Inspect the all synchronizer components for wear or damage Install a new components as necessary ...

Page 2877: ...OTE Reposition the output shaft on the press with the input shaft end facing upward Remove and discard the snap ring then using the special tool remove the third fourth gear synchronizer assembly the third gear synchronizer blocking ring and the third gear Inspect the gear for broken or cracked teeth Install a new gear as necessary ...

Page 2878: ...k springs for distortion Install a new synchronizer as necessary 12 Inspect the synchronizer blocking rings Check for wear or damage Install new synchronizer blocking rings as necessary Check the clearance between the synchronizer blocking ring and the gear Position the blocking ring onto the gear Make sure the correct blocking ring is measured with the correct gear and that the blocking ring is f...

Page 2879: ...Apply petroleum jelly to the bearing 4 Install third gear the third gear synchronizer blocking ring and the third fourth gear synchronizer assembly Position the output shaft with the output end facing upward Using the special tool press the third fourth gear synchronizer assembly into place Install the synchronizer body with the groove facing third gear Stop press operation before keys engage the ...

Page 2880: ...5 Install a new snap ring 6 Install the second gear needle bearing Apply petroleum jelly to the bearing 7 Install second gear ...

Page 2881: ...nd gear synchronizer assembly Position the output shaft with the output end facing downward Using the special tools press the first second gear synchronizer assembly into place Install the synchronizer with the groove on the sleeve facing first gear Stop press operation before keys engage the blocking ring slots Lift and rotate the second gear and the blocking ring until the keys are seated in the...

Page 2882: ...10 Install the first gear synchronizer thrust washer the inner cone the friction cone and the first gear synchronizer blocking ring 11 Install a new snap ring ...

Page 2883: ...e bearing Apply petroleum jelly to the bearing 13 Install first gear Rotate the gear to align the gear slots with the inner cone tabs 14 Install a new rear output shaft bearing 15 Using the special tools install the fifth driven gear ...

Page 2884: ......

Page 2885: ...n T56 2003 Mustang Workshop Manual Special Tool s Plate Bearing Oil Seal 205 090 T75L 1165 B Puller Bearing 205 D064 D84L 1123 A Installer Drive Pinion Bearing Cone 205 004 T53T 4621 B Remover Installer Bearing Tube 308 025 T75L 7025 C Installer Output Shaft Rear Bearing 308 401 Adapter for 303 224 Handle 205 153 T80T 4000 W ...

Page 2886: ... 7113 Countershaft 3 Countershaft rear bearing 4 Thrust washer 5 Sixth gear needle bearing 6 Sixth gear 7 Synchronizer blocking ring 8 Spacer 9 Snap ring 10 Fifth sixth synchronizer assembly 11 Fifth gear 12 Fifth gear needle bearing 13 Countershaft extension 14 Countershaft extension bearing ...

Page 2887: ...cial tool and a press remove the countershaft front bearing 4 Place the special tool in a vise Position the countershaft extension in the tool with the sixth drive gear facing upward Remove the fifth sixth shift fork 5 Remove the sixth drive gear 6 Remove the sixth drive gear needle bearing ...

Page 2888: ...synchronizer blocking ring 8 Remove and discard the fifth sixth synchronizer snap ring 9 Using the special tool press the fifth sixth synchronizer and the fifth drive gear off the shaft 10 Remove the fifth drive gear needle bearing ...

Page 2889: ...ronizer Check for worn nicked or broken teeth Install a new synchronizer as necessary Check keys for wear or distortion Install a new synchronizer as necessary Check springs for distortion Install a new synchronizer as necessary 15 Inspect the fifth sixth synchronizer blocking rings Check for wear or damage Install new synchronizer blocking rings as necessary Check the clearance between the synchr...

Page 2890: ... the blocking ring The measurement should be the same around the entire circumference If the clearance is less than 0 38 mm 0 015 in install new blocking rings 16 Using the special tools install the countershaft rear bearing 17 Using the special tools install the countershaft front bearing ...

Page 2891: ...18 Using the special tools install the countershaft extension bearing 19 To assemble reverse the disassembly procedure Assemble the synchronizer assembly before installing ...

Page 2892: ......

Page 2893: ...ver and remove the second spring Remove the sliding sleeve and the synchronizer struts from the hub 3 CAUTION Match the alignment marks made during disassembly The sleeve and the hub have an extremely close fit Hold the sleeve and hub square to prevent jamming Do not force the sleeve onto the hub Assemble the synchronizer as follows Position the synchronizer sleeve on the hub Make sure to align ke...

Page 2894: ......

Page 2895: ...k and shift link Separate the link from the fork SECTION 308 03C Manual Transaxle Transmission T56 2003 Mustang Workshop Manual Item Part Number Description 1 First second shift fork pad 2 First second shift fork 3 Interlock plate 4 Shift link 5 First second third fourth shift rail 6 Gear select solenoid lever 7 Roll pin 8 Selector pin 9 Roll pin 10 Shift link 11 Third fourth shift fork pad 12 Thi...

Page 2896: ...ch drift and a hammer remove and discard the roll pins Slide the collar and the reverse shift lever from the shift rail Slide off the fifth sixth shift lever and shift link 3 Inspect the shift rail components Check the rails shift forks shift levers and shift links for wear or damage Install new components as necessary Check the shift fork pads for wear Install new pads as necessary 4 To assemble ...

Page 2897: ......

Page 2898: ...SEMBLIES Extension Housing Disassembly and Assembly SECTION 308 03C Manual Transaxle Transmission T56 2003 Mustang Workshop Manual Special Tool s Installer Bearing Cup 204 039 T77F 1217 B Adapter for 303 224 Handle 205 153 T80T 4000 W ...

Page 2899: ...nnel 4 Case plug 5 Reverse idler shaft bracket 6 Reverse idler gear thrust washer 7 7141 Reverse idler gear 8 Reverse idler gear needle bearing 9 7140 Reverse idler gear shaft 10 7052 Extension housing seal 11 Snap ring 12 Mainshaft bearing cup 13 Output shaft speed OSS sensor 14 Reverse lockout solenoid 15 O ring ...

Page 2900: ...t and the output shaft speed OSS sensor 2 Remove the bolt and the reverse lockout solenoid 3 Remove the bolts and the reverse idler shaft bracket 4 Remove the reverse idler gear thrust washer 16 7A039 Extension housing ...

Page 2901: ...ng and countershaft extension bearing cup Inspect the needle bearing for wear or damage Install a new bearing as necessary Inspect the bearing cup for wear or damage Install a new bearing and bearing cup as necessary 7 Remove the reverse idler gear thrust washer and the reverse idler gear shaft 8 Remove the countershaft extension bearing shim and the fluid funnel ...

Page 2902: ...TE If the mainshaft bearing was install new install a new bearing cup Position the extension housing with the seal facing upward Using a brass drift remove the mainshaft bearing cup 11 Remove and discard the extension housing seal ...

Page 2903: ...ing for cracks If the housing is cracked install a new housing If the sealing surface has nicks or scratches use a soft stone or crocus cloth to remove 13 Using the special tools install the mainshaft bearing cup 14 Using a suitable driver install the extension housing seal Install the seal with the drain hole at the six o clock position 15 To assemble reverse the disassembly procedure ...

Page 2904: ...or wear or damage Install a new plate as necessary 2 Remove the case magnets SECTION 308 03C Manual Transaxle Transmission T56 2003 Mustang Workshop Manual Special Tool s Handle 205 D055 D81L 4000 A Installer Bearing Cup 204 039 T77F 1217 B Installer Drive Pinion Bearing Cup 205 054 T71P 4616 A Installer Rear Axle Oil Seal 205 155 T80T 4000 Y ...

Page 2905: ...switch 4 Using the special tools remove the countershaft bearing cup 5 Using a brass drift remove mainshaft bearing cup 6 Inspect the countershaft and mainshaft bearing cups for wear or damage Install new components as necessary ...

Page 2906: ... scratches use a soft stone or crocus cloth to remove 8 NOTE If a new countershaft bearing is being installed install a new bearing cup Always install new bearings and cups in a set Using the special tools install the countershaft bearing cup 9 NOTE If a new mainshaft bearing is being installed install a new bearing cup Always install new bearings and cups in a set Using the special tools install ...

Page 2907: ......

Page 2908: ... equivalent Holding Fixture Transmission 307 003 T57L 500 B Remover Installer Bearing Tube 308 025 T75L 7025 C Installer Bearing Cup 204 039 T77F 1217 B Adapter for 303 224 Handle 205 153 T80T 4000 W Installer Axle Shaft Oil Seal 205 123 T78P 1177 A Material Item Specification DEXRON III ATF Transmission Fluid XT 2 QDX or equivalent DEXRON III Premium Long Life Grease ESA M1C75 B ...

Page 2909: ...ont countershaft bearing was installed install new bearing cups Install the input shaft bearing cup and the countershaft bearing cup Do not install the shims at this time 4 Install the input shaft 5 Install the mainshaft onto the input shaft XG 1 C K or T Threadlock and Sealer E0AZ 19554 AA WSK M2G351 A5 type II Black Non Acid Cure Silicone Rubber E7TZ 19562 A ESL M4G273 A ...

Page 2910: ...6 Install the countershaft Lift the mainshaft upward tilt the countershaft and install 7 Install the transmission case and tighten the bolts ...

Page 2911: ...oad on the input shaft Record the measurement 9 Reposition the special tool on the countershaft Place the tip of the dial between the fingers on the countershaft 10 NOTE Rotate the countershaft to seat the bearings Using the special tools measure the countershaft gear end play by pushing upward on the countershaft Record the measurement Unscrew the installer from the handle Insert the handle into ...

Page 2912: ...11 Remove the bolts and the transmission case 12 Remove the countershaft ...

Page 2913: ...13 Remove the mainshaft 14 Remove the input shaft ...

Page 2914: ...cial tools install the new input shaft seal 17 Using the recorded end play measurements select and install the appropriate shims to achieve the proper end play Install the front input shaft bearing cup and the front countershaft bearing cup Lubricate the bearing cups with petroleum jelly ...

Page 2915: ...ng 19 Assemble the shift rail assembly to the mainshaft then install the mainshaft and shift rail as an assembly Rotate the mainshaft to engage the fourth gear synchronizer blocking ring with the synchronizer keys 20 Lift up the mainshaft then install the countershaft ...

Page 2916: ...ate Apply a bead of silicone rubber to the sealing surface on the transmission adapter plate Install the spring and detent ball into the front offset lever then install the transmission case and the front offset lever Make sure the transmission is in neutral to keep the third fourth gear shift rail from engaging Compress the front offset lever against the guide plate when installing Tighten the bo...

Page 2917: ... Pull up on the fifth sixth shift rail to align the slot of the interlock plate with the guide bolt hole 24 Install a new front offset lever roll pin Install the pin until it is flush with the lever 25 Apply threadlock and sealer to the threads of the shift dent then install the shift detent assembly ...

Page 2918: ...bly and the fifth sixth gear shift fork Make sure the splines are fully engaged 28 NOTE Remove the countershaft extension shim from the extension housing Install the extension housing and tighten the bolts 29 NOTE Rotate the transmission to the vertical position Using the special tools measure the countershaft extension end play by pushing upward on the countershaft extension Record the measuremen...

Page 2919: ...t and install the appropriate shims to achieve the proper end play Install the countershaft extension bearing cup Lubricate the bearing cup with petroleum jelly 32 Install the fifth sixth shift fork snap ring 33 Using the special tool press the fifth sixth driven gear Align the splines of the fifth sixth driven gear with the drive gear on the countershaft extension ...

Page 2920: ...er as an assembly Align the pockets in the blocking ring with the struts in the synchronizer 35 Install the reverse shift fork snap ring 36 Install a new reverse gear synchronizer snap ring 37 Install the reverse gear needle bearing and the reverse gear synchronizer blocking ring ...

Page 2921: ...38 Install the reverse gear wave washer 39 Install reverse gear 40 Install the reverse gear thrust washer 41 Install a new reverse gear snap ring ...

Page 2922: ...mainshaft roller bearing and the upper spacer 43 Install the rear mainshaft roller bearing snap ring 44 Install a new output speed shaft OSS sensor tone wheel lower retaining ring 45 Using the special tool install the OSS sensor tone wheel ...

Page 2923: ...sealer to the threads of the plug then install the plug into the transmission adapter plate 49 Clean the mating surfaces of the transmission main case and the extension housing Apply a bead of silicone rubber to the sealing surface on the transmission case Install the extension housing and tighten the bolts ...

Page 2924: ...e pin until it is flush with the lever 51 Install the vent hose 52 NOTE Before installing the transmission the ball stud the clutch release lever and the input shaft guide tube must be cleaned and lubricated Install the clutch release lever and the clutch release hub and bearing ...

Page 2925: ......

Page 2926: ...n to clutch adapter housing bolts 2 Connect the output shaft speed OSS sensor electrical connector 3 Connect the reverse lamp electrical connector SECTION 308 03C Manual Transaxle Transmission T56 2003 Mustang Workshop Manual Material Item Specification DEXRON III ATF Transmission Fluid XT 2 QDX or equivalent DEXRON III Pipe Sealant with Teflon D8AZ 19554 A or equivalent WSK M2G350 A2 Premium Long...

Page 2927: ...ect the wiring harness to the transmission 5 Connect the clutch release cable to the clutch release fork 6 Install the clutch release lever cover and bolt 7 Install the transmission crossmember and the bolts ...

Page 2928: ...n flange and the driveshaft slip yoke and transmission output shaft Install the driveshaft For additional information refer to Section 205 01 11 Fill the transmission to capacity with the specified transmission fluid Apply sealant to the fill plug threads and install the fill plug The total fill capacity is 3 9L 4 1 qt 12 Lower the vehicle 13 Connect the reverse lockout solenoid electrical connect...

Page 2929: ...rshift lever and the bolts 15 Install the lower gearshift lever boot and the bolts 16 Install the upper gearshift lever and the bolts 17 Connect the cigar lighter electrical connector Install the console panel gearshift plate ...

Page 2930: ...18 Install the gearshift lever knob ...

Page 2931: ...ECTION 309 00 Exhaust System 2003 Mustang Workshop Manual Torque Specifications Description Nm lb ft Dual converter to exhaust manifold nuts 40 30 Sleeve U bolt nuts 55 41 Dual converter to inlet pipe flange nuts 35 26 ...

Page 2932: ... 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 contains dual three way catalytic converters has a crossover pipe downstream of the three way catalytic converters 4 6L has two upstream heated oxygen sensors mounted before the three way catalytic converters the production muffler and tai...

Page 2933: ... 5260 Insulator bracket assembly RH 4 5260 Insulator bracket assembly LH 5 5A246 Insulator bracket tailpipe 2 req d 6 5230 Muffler LH Item Part Number Description 1 5F250 Dual converter assembly 2 5230 Muffler RH 3 5260 Insulator bracket assembly RH 4 5260 Insulator bracket assembly LH 5 5230 Muffler LH ...

Page 2934: ......

Page 2935: ...e or missing exhaust manifold fasteners or gaskets Loose heated oxygen or catalyst monitor sensor REPAIR as necessary Exhaust system misalignment ALIGN exhaust system Broken or loose catalyst internal components LOOSEN all fasteners joining the exhaust system and SHAKE the system to isolate the concern REPAIR as necessary Loss of power Kinked or damaged exhaust pipe Clogged three way catalytic con...

Page 2936: ......

Page 2937: ...on 100 02 2 Support the rear axle with a suitable jack 3 Remove the upper arm to differential bolt 4 Remove the nut and bolt and disconnect the rear shock absorbers 18124 from the axle housing Discard the nut 5 Lower the rear axle 6 Remove the dual converter assembly flange nuts SECTION 309 00 Exhaust System 2003 Mustang Workshop Manual ...

Page 2938: ...Remove the exhaust hanger insulators 9 Remove the muffler 5230 10 CAUTION Do not use oil or grease based lubricants on insulators as they deteriorate the rubber NOTE A soap and water solution will ease installation of the exhaust hanger insulators To install reverse the removal procedure ...

Page 2939: ......

Page 2940: ...r arm to differential bolt 3 Remove the nut and bolt and disconnect the rear shock absorbers 18124 from the axle housing Discard the nut 4 Lower the rear axle 5 Remove the dual converter assembly nuts RH shown LH similar 6 Remove the RH intermediate exhaust hanger insulator SECTION 309 00 Exhaust System 2003 Mustang Workshop Manual ...

Page 2941: ... muffler 5230 from the rear exhaust hanger insulator 5260 8 Remove the LH muffler 5230 from the rear exhaust hanger insulator 5260 9 Remove the LH intermediate exhaust hanger insulator 10 Remove the LH and RH mufflers ...

Page 2942: ...not use oil or grease based lubricants on the insulators as they deteriorate the rubber NOTE A soap and water solution will ease installation of the exhaust hanger insulators To install reverse the removal procedure ...

Page 2943: ...rmation refer to Section 100 02 2 NOTE RH side shown LH side similar Remove the dual converter assembly nuts 3 Remove the RH exhaust hanger insulator 5260 4 Remove the LH exhaust hanger insulator 5260 5 Remove the RH intermediate exhaust pipe hanger insulator SECTION 309 00 Exhaust System 2003 Mustang Workshop Manual ...

Page 2944: ...6 Remove the LH exhaust pipe hanger insulator 7 Remove the RH exhaust pipe hanger insulator 8 Remove the LH exhaust pipe hanger insulator 9 Remove the RH and LH mufflers ...

Page 2945: ...not use oil or grease based lubricants on the insulators as they deteriorate the rubber NOTE A soap and water solution will ease installation of the exhaust hanger insulators To install reverse the removal procedure ...

Page 2946: ...hen repairing the exhaust system or removing exhaust components disconnect all heated oxygen sensors HO2S 9F472 and catalyst monitor sensors at the wiring connectors to prevent damage to the sensors and wiring harnesses Disconnect the RH and LH HO2S connectors 3 Disconnect the RH and LH catalyst monitor sensor connectors 4 Remove the dual converter assembly nuts SECTION 309 00 Exhaust System 2003 ...

Page 2947: ...ge nuts 6 Remove the LH exhaust manifold flange nuts 7 Remove the dual converter 5F250 assembly 8 If necessary use the two spot welds as a baseline measure 226 8 mm 9 07 in and cut the pipe 9 Remove 13 mm 0 52 in from the LH dual converter ...

Page 2948: ...o manifold nuts 2 Position the RH dual converter pipe Snug the RH converter to manifold nuts 3 If necessary position the LH and RH dual converter pipes into the sleeve and install the clamps Tighten the clamps to 55 Nm 41 lb ft 4 Install the dual converter assembly nuts ...

Page 2949: ...Tighten the LH converter to manifold nuts 6 Tighten the RH converter to manifold nuts 7 Connect the RH and LH HO2S connectors 8 Connect the RH and LH catalyst monitor sensor connectors 9 Lower the vehicle ...

Page 2950: ......

Page 2951: ... system or removing the exhaust components disconnect all heated oxygen sensors HO2S 9F472 at the wiring connectors to prevent damage to the heated oxygen sensors and wiring harness Disconnect the downstream RH and LH heated oxygen sensor connectors 9F472 3 Disconnect the two upstream RH and LH catalyst monitor sensor connectors 4 Remove the dual converter assembly nuts RH shown LH similar SECTION...

Page 2952: ...fold flange nuts 7 Remove the dual converter H pipe 8 If necessary use the center of the LH flange as a baseline measure 67 mm 2 68 in and cut the cross over pipe 9 If necessary use the center of the RH flange as a baseline measure 83 9 mm 3 35 in and cut the cross over pipe ...

Page 2953: ...ll the dual converter assembly nuts RH shown LH similar 3 If necessary position the sleeve and clamps Tighten the clamps to 55 Nm 41 lb ft 4 Tighten the four converter to manifold nuts 5 Connect the two upstream RH and LH heated oxygen sensor connectors 6 Connect the two downstream RH and LH catalyst monitor sensor connectors ...

Page 2954: ......

Page 2955: ...nual 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 ...

Page 2956: ...related components Highly flammable mixtures are always present and may be ignited resulting in possible personal injury SECTION 310 00 Fuel System General Information 2003 Mustang Workshop Manual Item Part Number Description 1 9341 Inertia fuel shutoff switch 2 9F593 Fuel injector 3 9155 Fuel filter 4 9002 Fuel tank 5 9H307 Fuel pump module and flange assembly ...

Page 2957: ...593 for each cylinder The fuel injectors are mounted to the intake manifold fuel injectors are supplied with pressurized fuel from the fuel pump 9350 through the fuel injection supply manifold 9D280 fuel injection supply manifold is controlled by the electronic fuel delivery module which is enabled by the powertrain control module PCM 12A650 ...

Page 2958: ...DIAGNOSIS AND TESTING Fuel System Refer to the Powertrain Control Emissions Diagnosis PC ED manual SECTION 310 00 Fuel System General Information 2003 Mustang Workshop Manual ...

Page 2959: ... 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 Place the fuel in a sui...

Page 2960: ......

Page 2961: ...tional information refer to Section 414 01 2 Remove the fuel tank filler cap 3 Insert the hose guide into the filler neck 4 NOTE Insert the hose until the stop contacts the guide tube If the stop does not contact the guide tube remove the hose and repeat the procedure Insert the chamfered end of the hose into the filler neck through the guide tube SECTION 310 00 Fuel System General Information 200...

Page 2962: ...5 Attach the Fuel Storage Tanker to the hose and remove the fuel 6 Remove the hose and the hose guide ...

Page 2963: ...components the fuel system pressure must be relieved to prevent accidental spraying of fuel causing personal injury or a fire hazard 1 Relieve the fuel system pressure For additional information refer to Pressure Relief in this section 2 Remove the fuel tube clip SECTION 310 00 Fuel System General Information 2003 Mustang Workshop Manual Special Tool s Disconnect Tool Spring Lock Coupling 3 8 inch...

Page 2964: ...3 Install the Spring Lock Coupler Tool 4 Close and push the Spring Lock Coupler Tool into the open side of the cage 5 Separate the fitting 6 Remove the Spring Lock Coupler Tool ...

Page 2965: ...Connect 1 NOTE Inspect and clean both the coupling ends Lubricate the O ring seals with clean engine oil Connect the fitting Pull on the fitting to make sure it is fully engaged Install the safety clip ...

Page 2966: ...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 Relieve the fuel system pressure For additional information refer to Pressure Relief in this section 2 Disconnect the safety clip from the male hose 3 Install the Fuel Line Disconnect Set and push into the fitting SECTION 310 00 Fuel Syste...

Page 2967: ...s for damage Connect 1 NOTE Lubricate the tube end with clean engine oil to ease assembly Connect the fitting Align the tube to the fitting and push until you hear a click 2 Pull on the fitting to make sure it is fully engaged then install the safety clip ...

Page 2968: ......

Page 2969: ...ents the fuel system pressure must be relieved to prevent accidental spraying of fuel causing possible personal injury or a fire hazard CAUTION Do not use any tools The use of tools may cause a deformity in the clip components which may cause fuel leaks 1 Relieve the fuel system pressure For additional information refer to Pressure Relief in this section 2 Remove the shipping tab by bending 3 Spre...

Page 2970: ... the tube Connect 1 NOTE Apply a light coat of clean engine oil Clean and inspect the fitting and the tube for damage 2 Insert the R clip into the fitting 3 Insert the tube in the fitting and push together until a click is heard ...

Page 2971: ...4 Pull on the connection to make sure it is fully engaged ...

Page 2972: ...ectrical spark occurring possibly causing a fire or explosion if fuel vapor or fuel liquid is present in the area Disconnect the battery ground cable 2 Disconnect the vapor tube from the fitting 1 Squeeze the fitting 2 Disconnect the vapor tube from the fitting Connect 1 Clean and inspect the fitting and the tube for damage 2 Push the tube into the fitting until it snaps in place 3 Pull on the con...

Page 2973: ......

Page 2974: ...Specification Lubricants Premium Long Life Grease XG 1 C or XG 1 K ESA M1C75 B Serfactant Merpol ESE M99B144 B Torque Specifications Description Nm lb ft lb in Fuel tank support strap bolts 35 26 Fuel tank filler pipe support bracket bolt 8 71 Fuel delivery module bolts 10 89 Fuel filter bracket bolts 10 89 ...

Page 2975: ...tors a single fuel line accommodating the returnless fuel system a fuel injection supply manifold which contains a differential pressure sensor and a fuel temperature sensor a fuel pump and sender assembly which provides pressurized fuel to the engine and contains an inlet filter a check valve which maintains system pressure after the pump is shut off a pressure relief valve for overpressure prote...

Page 2976: ...DIAGNOSIS AND TESTING Fuel Tank And Lines Refer to the Powertrain Control Emissions Diagnosis PC ED manual SECTION 310 01 Fuel Tank and Lines 2003 Mustang Workshop Manual ...

Page 2977: ...d prior to fuel system service to prevent possible personal injury or a fire hazard 1 Disconnect the battery For additional information refer to Section 414 01 2 Relieve the fuel system pressure For additional information refer to Section 310 00 3 Drain the fuel tank For additional information refer to Section 310 00 4 Raise the vehicle For additional information refer to Section 100 02 5 Remove t...

Page 2978: ...fitting at the left front of the fuel tank 8 Disconnect the EVAP canister tube and hose 9 Place a safety support under the fuel tank 10 Remove the front bolts from the fuel tank support straps and swing the LH strap out of the way ...

Page 2979: ...alve will occur Cut outer edge of pipe to tank grommet to facilitate pipe removal and carefully remove the grommet from the fuel tank Take care to avoid damage to the filler pipe check valve 14 Lower the fuel tank from the vehicle Installation 1 CAUTION Lubricate the filler pipe check valve area and the tank to filler pipe grommet with Serfactant prior to assembly or damage to the filler pipe chec...

Page 2980: ...To install reverse the removal procedure ...

Page 2981: ......

Page 2982: ...h fuel injected engines will remain pressurized for long periods of time after engine shutdown Fuel system pressure must be relieved prior to fuel system service to prevent possible personal injury or a fire hazard 1 Remove the fuel tank For additional information refer to Fuel Tank in this section 2 Slide the strap and the retaining pin into the recess and remove the strap retaining pin 3 Remove ...

Page 2983: ......

Page 2984: ...en the bolts in the sequence shown Remove the module assembly flange bolts 3 Clean the area around the fuel delivery module mounting flange 4 Lift the fuel pump carefully detach the fuel float arm and remove the fuel pump from the fuel tank 5 NOTE Install a new fuel pump O ring To install reverse the removal procedure SECTION 310 01 Fuel Tank and Lines 2003 Mustang Workshop Manual ...

Page 2985: ......

Page 2986: ...from the filler pipe housing 3 Remove the bolts from the filler pipe rubber boot to floor pan 4 Remove the hose attached to the upper part of the pipe 5 Rotate the pipe downward to clear the filler pipe pocket and pull it into the trunk area Installation 1 To install reverse the removal procedure SECTION 310 01 Fuel Tank and Lines 2003 Mustang Workshop Manual ...

Page 2987: ...e hazard 1 Disconnect the battery For additional information refer to Section 414 01 2 Relieve the fuel system pressure For additional information refer to Section 310 00 3 Raise the vehicle For additional information refer to Section 100 02 4 Disconnect the filter push connect fittings For additional information refer to Section 310 00 5 Unsnap the filter from the bracket and remove Installation ...

Page 2988: ......

Page 2989: ...additional information refer to Section 414 01 2 Open the luggage compartment 3 Remove the inertia fuel shutoff IFS switch electrical connector and screws and remove the switch Installation 1 To install reverse the removal procedure SECTION 310 01 Fuel Tank and Lines 2003 Mustang Workshop Manual ...

Page 2990: ...r Surrounding components such as wiring hoses sound insulator and floor covering must not contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft The sliding inner member of the accelerator cable should not be lubricated and is not serviceable SECTION 310 02 Acceleration Control 2003 Mustang Workshop Manual Item Part Number Description 1 9725 Accelerator pedal ...

Page 2991: ......

Page 2992: ... pedal and shaft damaged linkage damaged accelerator cable high engine idle speed damaged throttle body Symptom Chart Condition Possible Sources Action Excessive effort needed to depress accelerator pedal and shaft Worn accelerator lever pivot bushing INSTALL a new accelerator pedal and shaft Accelerator cable binding INSTALL a new accelerator cable Worn or damaged throttle body INSTALL a new thro...

Page 2993: ... to Section 303 04A or Section 303 04B High engine idle speed Kinked accelerator cable INSTALL a new accelerator cable Foreign object caught in accelerator pedal linkage CHECK the accelerator pedal linkage Incorrect engine idle speed REFER to the Powertrain Control Emissions Diagnosis PC ED manual for diagnosis and testing of the idle control system ...

Page 2994: ...h the accelerator cable nylon bushing out of the accelerator pedal and shaft arm 2 Remove the accelerator pedal and shaft Remove the nuts Remove the accelerator pedal and shaft 3 To install reverse the removal procedure SECTION 310 02 Acceleration Control 2003 Mustang Workshop Manual ...

Page 2995: ......

Page 2996: ...l 3 Disconnect the accelerator cable from the throttle body by rotating the throttle body full open and aligning the cable with the release slot 4 Disconnect the accelerator cable from the retaining bracket by compressing the locking tabs and back feeding the cable through the bracket and out of the engine compartment 5 To install reverse the removal procedure SECTION 310 02 Acceleration Control 2...

Page 2997: ......

Page 2998: ... cable to the dash panel 3 Disconnect the accelerator cable from the throttle body by rotating the throttle body full open and aligning the cable with the release slot 4 Disconnect the accelerator cable from the retaining bracket by compressing the locking tabs and back feeding the cable through the bracket and out of the engine compartment SECTION 310 02 Acceleration Control 2003 Mustang Workshop...

Page 2999: ...5 To install reverse the removal procedure ...

Page 3000: ...ble nylon bushing out of the accelerator pedal and shaft arm 2 Disconnect the accelerator cable from the throttle cam 3 Depress the tabs and disconnect the accelerator cable from the bracket 4 Release the clip and position the accelerator cable aside SECTION 310 02 Acceleration Control 2003 Mustang Workshop Manual ...

Page 3001: ...5 Remove the bolts and the accelerator cable 6 To install reverse the removal procedure ...

Page 3002: ...onnect the accelerator cable from the throttle body by rotating the throttle body full open and aligning the cable with the release slot 3 Compress the accelerator cable locking tabs and disconnect the accelerator cable from the accelerator cable bracket 4 Remove the bolts and the accelerator cable bracket 5 To install reverse the removal procedure SECTION 310 02 Acceleration Control 2003 Mustang ...

Page 3003: ......

Page 3004: ...310 03 2 Disconnect the accelerator cable from the throttle body by rotating the throttle body full open and aligning the cable with the release slot 3 Compress the accelerator cable locking tabs and disconnect the accelerator cable from the accelerator cable bracket 4 Remove the spring 5 Remove the bolts and the accelerator cable bracket SECTION 310 02 Acceleration Control 2003 Mustang Workshop M...

Page 3005: ...6 To install reverse the removal procedure ...

Page 3006: ...ccelerator cable and speed control cable 2 Depress the tabs and disconnect the accelerator cable and speed control cable from the accelerator cable bracket 3 Remove the bolts and the accelerator cable bracket 4 To install reverse the removal procedure SECTION 310 02 Acceleration Control 2003 Mustang Workshop Manual ...

Page 3007: ......

Page 3008: ...eleration Control 2003 Mustang Workshop Manual Torque Specifications Description Nm lb ft lb in Accelerator pedal and shaft nuts 18 13 Accelerator cable bracket Supercharged engine 10 89 Accelerator cable bolts Supercharged engine 4 35 ...

Page 3009: ...ntrol 2003 Mustang Workshop Manual Torque Specifications Description Nm lb ft lb in Battery ground cable 7 10 62 89 Horn contact screws 6 5 7 5 58 66 Speed control actuator switch screws 6 5 7 5 4 8 5 5 Speed control servo bracket bolt 7 62 ...

Page 3010: ...nents speed control actuator cable 9A825 deactivator switch output shaft sensor OSS speed control actuator switches 9C888 brake pedal position BPP switch 13480 speed control servo 9C735 clutch pedal position switch manual transmission only SECTION 310 03 Speed Control 2003 Mustang Workshop Manual ...

Page 3011: ...set speed if the vehicle is traveling over 48 km h 30 mph and the OFF switch has not been depressed NOTE The deactivator switch is provided as an additional safety feature Normally when the brake pedal is depressed an electrical signal from the brake lamp circuit to the speed control servo will deactivate the system Under increased brake pedal effort the deactivator switch will open and remove pow...

Page 3012: ... symptom and GO to the Symptom chart Symptom Chart NOTE New speed control diagnostic software is available in Version 12 or higher for the diagnostic tool When using this software it is necessary to use Next Generation Speed Control Adapter 007 00586 with the diagnostic tool NOTE Refer to the Wiring Diagrams for connector numbers stated in the Pinpoint Test Visual Inspection Chart Mechanical Elect...

Page 3013: ...5A Circuitry Brake pedal position BPP switch Speed control servo Go To Pinpoint Test C The speed control does not disengage when the clutch is applied Cluch pedal position CPP switch Speed control servo Go To Pinpoint Test D The speed control switch is inoperative COAST Speed control actuator switch Speed control servo Go To Pinpoint Test E The speed control switch is inoperative SET ACCEL Speed c...

Page 3014: ... greater than 10 volts Yes GO to A3 No GO to A2 A2 CHECK THE CIRCUIT 1205 BK FOR AN OPEN Key in OFF position Measure the resistance between speed control servo C122 Pin 10 Circuit 1205 BK harness side and ground Is the resistance less than 5 ohms Yes REPAIR Circuit 294 WH LB TEST the system for normal operation No REPAIR Circuit 1205 BK TEST the system for normal operation A3 CHECK DEACTIVATOR SWI...

Page 3015: ...rol servo C122 Pin 9 Circuit 636 OG harness side and deactivator switch C2210 Pin 2 Circuit 636 OG harness side Is the resistance less than 5 ohms Yes INSTALL a new deactivator switch REFER to Switch Deactivator TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation A6 CHECK THE SPEED CONTROL ACTUATOR SWITCH ON CIRCUITRY Measure the voltage between speed co...

Page 3016: ...Actuator Switch Measure the resistance between bottom of air bag sliding contact Pin 1 component side and top of air bag sliding contact Pin 3 component side Is the resistance less than 5 ohms Yes INSTALL a new speed control actuator switch REFER to Switch Speed Control Actuator TEST the system for normal operation No INSTALL a new air bag sliding contact REFER to Section 501 20B TEST the system f...

Page 3017: ...ator Switch Key in ON position Measure the voltage between bottom of air bag sliding contact Pin 1 component side and ground Is any voltage present Yes INSTALL a new air bag sliding contact REFER to Section 501 20B TEST the system for normal operation No INSTALL a new speed control actuator switch REFER to Switch Speed Control Actuator TEST the system for normal operation A12 CHECK THE SPEED CONTR...

Page 3018: ...peration If manual transmission GO to A14 A14 CHECK CIRCUIT 511 LG AND CIRCUIT 810 RD LG FOR AN OPEN Disconnect CPP Switch C2072 Measure the resistance between CPP Switch C2072 Pin 1 Circuit 511 LG harness side and ground Is the resistance less than 20 ohms Yes GO to A15 No REPAIR Circuit 511 LG and Circuit 810 LG RD as necessary TEST the system for normal operation A15 CHECK CIRCUIT 511 LG FOR AN...

Page 3019: ...17 CHECK THE SPEED CONTROL SERVO INSTALL a known good speed control servo Test drive the vehicle for correct operation Does the speed control operate correctly Yes INSTALL a new speed control servo REFER to Actuator Speed Control Servo TEST the system for normal operation No INSTALL a new PCM REFER to Section 303 14 TEST the system for normal operation Test Step Result Action to Take B1 CHECK THAT...

Page 3020: ...ctuator Speed Control Servo TEST the system for normal operation No INSTALL a new PCM REFER to Section 303 14 TEST the system for normal operation Test Step Result Action to Take C1 CHECK THE BPP SWITCH CIRCUITRY Key in OFF position Disconnect Speed Control Servo C122 Measure the voltage between speed control servo C122 Pin 4 Circuit 511 LG harness side and speed control servo C122 Pin 10 Circuit ...

Page 3021: ...rol servo C122 Pin 6 Circuit 848 DG OG harness side while pressing the speed control actuator switch COAST Is the resistance between 108 and 132 ohms Yes INSTALL a new speed control servo REFER to Actuator Speed Control Servo TEST the system for normal operation No INSTALL a new speed control actuator switch REFER to Switch Speed Control Actuator TEST the system for normal operation Test Step Resu...

Page 3022: ...essing the speed control actuator switch RESUME Is the resistance between 1 980 and 2 420 ohms Yes INSTALL a new speed control servo REFER to Actuator Speed Control Servo TEST the system for normal operation No INSTALL a new speed control actuator switch REFER to Switch Speed Control Actuator TEST the system for normal operation Test Step Result Action to Take H1 CHECK THE SPEED CONTROL ACTUATOR S...

Page 3023: ...Is the resistance less than 5 ohms INSTALL a new speed control actuator switch REFER to Switch Speed Control Actuator TEST the system for normal operation ...

Page 3024: ...nect the switch hook from the brake pedal 2 Depress the switch hook and plunger into the deactivator switch body until the adjustment locking tab snaps into place within the hook 3 Depress the brake pedal and reattach the switch hook SECTION 310 03 Speed Control 2003 Mustang Workshop Manual ...

Page 3025: ...et 2 Remove the speed control cable from the retaining clips 3 Remove the LH front wheel and tire assembly For additional information refer to Section 204 04 4 Position aside the LH front splash shield 1 Remove the pin type retainers 2 Remove the screws 3 Position aside the LH front splash shield 5 Depress the locking tab and rotate the speed control actuator cable cap to remove SECTION 310 03 Spe...

Page 3026: ...trol actuator cable from the speed control servo pulley 1 Gently push in the retaining spring 2 Disconnect the speed control cable slug from the speed control servo pulley Installation 1 To install reverse the removal procedure ...

Page 3027: ...ble from the throttle bracket 2 Remove the speed control cable from the retaining clips 3 Remove the LH front wheel and tire assembly For additional information refer to Section 204 04 4 Position aside the LH front splash shield Remove the pin type retainers Remove the screws 5 Depress the locking tab and rotate the speed control actuator cable cap to remove SECTION 310 03 Speed Control 2003 Musta...

Page 3028: ...6 Gently push in the retaining spring while disconnecting the speed control actuator cable from the speed control actuator pulley Installation 1 To install reverse the removal procedure ...

Page 3029: ...d cable 2 Remove the LH wheel and tire refer to Section 204 04 3 Position aside the LH front splash shield 1 Remove the pin type retainers 2 Remove the screws 3 Position aside the LH front splash shield 4 Disconnect the speed control servo electrical connector 5 Depress the locking tab and rotate the speed control actuator cable cap to remove SECTION 310 03 Speed Control 2003 Mustang Workshop Manu...

Page 3030: ...trol cable slug from the speed control servo pulley 8 Remove the speed control servo 1 Remove the bolts 2 Remove the speed control servo Installation 1 NOTE When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km 10 mi or more to relearn the strategy To install reverse the remov...

Page 3031: ......

Page 3032: ... the upper deactivator pivot Installation 1 NOTE When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km 10 mi or more to relearn the strategy To install reverse the removal procedure Adjust the deactivator switch refer to Switch Adjustment Deactivator SECTION 310 03 Speed Contr...

Page 3033: ......

Page 3034: ...move the steering wheel rear cover 1 Remove the screws 2 Remove the steering wheel rear cover 3 Remove the ribbon harness from the clips 4 Remove the horn contact electrical connectors 5 Remove the right side horn contact 1 Remove the screws 2 Remove the contact SECTION 310 03 Speed Control 2003 Mustang Workshop Manual ...

Page 3035: ...6 Remove the speed control actuator switch assembly 1 Remove the screws 2 Remove the speed control actuator switch assembly Installation 1 To install reverse the removal procedure ...

Page 3036: ......

Page 3037: ...r 1 45 mm 0 057 in Magnetic Clutch Air gap clearance 0 35 0 75 mm 0 014 0 030 in Dual Function Pressure Switch V8 a Fan on open 2 137 2 344 kPa 310 340 psi Fan off close 1 655 2 137 kPa 240 310 psi Clutch off open 2 999 3 275 kPa 435 475 psi Clutch on closed 1 517 1 931 kPa 220 280 psi Pressure Cutoff Switch V6 a Open 2 999 3 275 kPa 435 475 psi Close 1 586 1 999 kPa 230 290 psi A C Cycling Switch...

Page 3038: ...t valve and the A C pressure relief valve the A C cycling switch the pressure cutoff switch V6 and the dual function pressure switch V8 location Torque Specifications Description Nm lb in Peanut fitting nut 8 71 ...

Page 3039: ...Do not allow any portion of the charged air conditioning system to become too hot The pressure in an air conditioning system rises as the temperature rises and temperatures of approximately 85 C 185 F can be dangerous Allow the engine to cool sufficiently prior to carrying out maintenance or serious burns and injury can occur CAUTION To avoid damaging the vehicle or A C components the following pr...

Page 3040: ... not remove the sealing caps from a new component until ready to install Refrigerant oil will absorb moisture from the atmosphere if left uncapped Do not open an oil container until ready to use and install the cap immediately after using Store the oil in a clean moisture free container Install a new O ring seal before connecting an open fitting Coat the fitting and the O ring seal with refrigeran...

Page 3041: ...ry voltage is above 8 5 volts during engine cranking When these conditions are present the powertrain control module PCM will activate the A C control relay prior to cranking of the engine The A C control relay engages the A C compressor for approximately 4 15 A C compressor revolutions or a maximum of 2 seconds depending upon vehicle application allowing the liquid refrigerant to be pushed from t...

Page 3042: ...press and can damage the A C compressor The refrigerant cycle is now repeated with the A C compressor again increasing the pressure and temperature of the refrigerant The A C cycling switch 19E561 interrupts compressor operation before the external temperature of the A C evaporator core gets low enough to cause the condensed water vapor excess humidity to turn to ice It does this by monitoring low...

Page 3043: ...lve port low side 2 19E561 A C cycling switch 3 19C836 Suction accumulator drier 4 19703 A C compressor 5 19D644 A C compressor pressure relief valve 6 19D594 A C pressure cutoff switch 7 19D701 A C charge valve port high side 8 19712 A C condenser core ...

Page 3044: ... A C registers A small amount of airflow from the side window demisters will be present Blended air temperature is available The A C compressor will operate if the outside temperature is above approximately 6 C 43 F The blower motor is on NORM A C When NORM A C is selected The air inlet door vacuum control motor is at no vacuum admitting only outside air into the passenger compartment 9 19D990 A C...

Page 3045: ...nly outside air into the passenger compartment The panel defrost door vacuum control motor is at full vacuum and the panel floor door vacuum control motor is at no vacuum directing airflow to the instrument panel A C registers A small amount of airflow from the side window demisters will be present The temperature can be adjusted to heat the air but the air cannot be cooled below the outside tempe...

Page 3046: ...uct A small amount of airflow from the side window demisters will be present The temperature can be adjusted to heat the air but the air cannot be cooled below the outside temperature The A C compressor will not operate The blower motor is on FLOOR DEFROST When FLOOR DEFROST is selected The air inlet door vacuum control motor is at no vacuum admitting only outside air into the passenger compartmen...

Page 3047: ... outside air into the passenger compartment The panel floor door and panel defrost door vacuum control motors are at no vacuum directing airflow to the defroster duct and the side window demisters The temperature can be adjusted to heat or cool the air below the outside temperature The A C compressor will operate if the outside air temperature is above approximately 6 C 43 F The blower motor is on...

Page 3048: ... A C control assembly 2 19E561 A C cycling switch 3 19D594 A C pressure cutoff switch V6 4 19D594 A C pressure cutoff switch V8 5 12A650 Powertrain control module 6 12B581 Constant control relay module 7 19703 A C compressor 8 19805 Blower motor ...

Page 3049: ...9 18591 Heater blower motor resistor ...

Page 3050: ... s Connector Refrigerant Pressure Line 412 093 T94P 19623 E Set A C Fittings 412 DS028 014 00333 D93L 19703 B or equivalent Vacuum Pump Kit 416 D002 D95L 7559 A or equivalent Breakout Box EEC V Control System 418 049 014 00950 T94L 50 EEC V Worldwide Diagnostic System WDS 418 F224 New Generation STAR NGS Tester 418 F052 or equivalent diagnostic tool Pressure Test Kit 014 R1072 or equivalent 77 III...

Page 3051: ...Vacuum Schematic Manual Climate Control System R 134a Manifold Gauge Set 176 R032A or equivalent Refrigerant Leak Detector 216 00001 or equivalent ...

Page 3052: ...rature blend door full heat position 6 19860 A C evaporator core 7 19A813 Air inlet door full vacuum position 8 Outside air inlet 9 18A318 Vacuum control motor air inlet door 10 Recirculated air inlet 11 19805 Blower motor 12 Vacuum from the engine intake manifold 13 19A563 A C vacuum check valve 14 19A566 A C vacuum reservoir tank and bracket 15 19B888 A C heater function selector switch ...

Page 3053: ...oor 20 Panel vent airflow Port No Hose Color Function 1 White Air inlet door 2 Red Panel floor door 3 Blue Panel floor door 4 Yellow Panel defrost door 5 Black Vacuum source 6 Not used Function Selector Switch Vacuum Application Chart Switch Port Color Function Function Selector Switch Position MAX A C A C Vent OFF Floor FLR DEF Defrost 1 White Recirc Fresh V NV NV V NV NV NV 2 Red Floor NV NV NV ...

Page 3054: ...ot allow the vehicle selection to be entered refer to the scan tool manual 5 Carry out the DATA LINK DIAGNOSTIC TEST using the scan tool If the scan tool responds with CKT 914 CKT 915 or CKT 70 ALL MODULE NO RESPONSE NOT EQUIPPED go to Communication System Diagnostics in Section 418 00 to diagnose network concern If the powertrain control module PCM is not listed for a communication concern turn t...

Page 3055: ...ling switch damaged A C system discharged low charge Function selector switch damaged A C pressure cut off switch damaged A C compressor clutch damaged Go To Pinpoint Test C The A C is always on Circuitry short open A C cycling switch A C heater function selector switch Constant control relay module Incorrect A C clutch air gap Go To Pinpoint Test D Insufficient A C cooling Restricted A C evaporat...

Page 3056: ...his DTC will set if the A C is turned on when carrying out the PCM self test P14642 CHECK PID ACCS WITH THE A C CONTROL DISCONNECTED Key in OFF position Disconnect Function Selector Switch C294c Key in ON position Enter the following diagnostic mode on the diagnostic tool PCM PID ACCS Does PID ACCS read ON Yes GO to P14643 No INSTALL a new function selector switch REFER to Section 412 04 REPEAT th...

Page 3057: ...ion Is there airflow from defroster outlets under all conditions Yes GO to A2 No If the airflow is from defroster outlets in all switch positions only under engine speed acceleration GO to A19 If the airflow is incorrect under one or more conditions GO to A13 If the airflow is correct under all conditions RETURN to the Symptom Chart A2 CHECK THE VACUUM SUPPLY HOSE Key in OFF position Verify the va...

Page 3058: ...5 A5 INSPECT THE VACUUM CHECK VALVE Key in OFF position Disconnect A C Vacuum Check Valve Inspect the A C vacuum check valve for an obstruction and correct operation Airflow through the A C vacuum check valve should be in the direction toward the engine engine connection site is marked VAC Is the A C vacuum check valve plugged or obstructed Yes INSTALL a new A C vacuum check valve TEST the system ...

Page 3059: ...rvoir tank Does the reservoir leak Yes INSTALL a new A C vacuum reservoir tank TEST the system for normal operation No RECONNECT the A C vacuum reservoir tank GO to A8 A8 CHECK THE SUPPLY HOSE Disconnect Function Selector Switch Supply Hose Use a vacuum pump to leak test the function selector switch supply hose Does the function selector switch supply hose leak Yes REPAIR or INSTALL a new function...

Page 3060: ...ion selector switch TEST the system for normal operation No RECONNECT the function selector switch vacuum connector GO to A12 A11 CHECK THE SUPPLY HOSE FOR OBSTRUCTIONS Disconnect Mode Selector Switch Supply Hose Connect a vacuum pump to the supply hose and try to pull a vacuum If the vacuum pump can pull a vacuum the hose is plugged If the vacuum pump pulls a partial vacuum the hose is restricted...

Page 3061: ... pump can pull a vacuum the hose is plugged If the vacuum pump pulls a partial vacuum the hose is restricted Is a hose plugged or restricted Yes INSTALL a new vacuum hose TEST the system for normal operation No GO to A15 A15 CHECK THE VACUUM HARNESS Compare the vacuum hose color in each vacuum harness to the vacuum diagram Does the hose color agree with the schematics Yes GO to A16 No INSTALL a ne...

Page 3062: ...o A18 A18 CHECK THE VACUUM HOSE Disconnect the suspect hose Plug one end of the hose and attach a vacuum pump to the other end Check for a leak in the hose Does the vacuum hose leak Yes REPAIR or INSTALL a new hose TEST the system for normal operation No GO to A19 A19 CHECK THE VACUUM CONTROL MOTOR Disconnect Vacuum Control Motor Check the vacuum control motor for leaks with a vacuum pump Yes GO t...

Page 3063: ...tion Test Step Result Action to Take B1 CHECK FOR CORRECT ENGINE COOLANT LEVEL Key in OFF position Check the engine coolant level when hot and cold Is the engine coolant at the correct level hot cold as indicated on the engine coolant recovery reservoir Yes GO to B2 No GO to B3 B2 CHECK FOR HOT WATER TO THE HEATER CORE INLET HOSE WARNING The heater core inlet hose will become too hot to handle and...

Page 3064: ...OSE FOR HOT WATER Feel the heater core outlet hose Is the heater core outlet hose cool or cold Yes TEST the heater core for a plugged or partially plugged condition REFER to Section 303 03A or Section 303 03B No GO to Pinpoint Test E Test Step Result Action to Take C1 CHECK THE PCM PID WACF Connect the diagnostic tool Turn the function selector to the OFF position Key in ON position Enter the foll...

Page 3065: ...C read ON Yes GO to C20 No GO to C5 C5 CHECK THE INPUT SIGNAL TO THE PCM Key in OFF position Disconnect PCM C175 Key in ON position Measure the voltage at PCM C175 41 circuit 198 DG OG harness side and ground Is the voltage reading greater than 10 volts Yes INSTALL a new powertrain control module TEST the system for normal operation No GO to C6 C6 CHECK THE REFRIGERANT PRESSURE Key in OFF position...

Page 3066: ...ng Switch C130 Measure the resistance between the function selector switch C294c 4 circuit 348 VT harness side and ground Is the resistance reading less than 10 000 ohms Yes REPAIR circuit 348 VT TEST the system for normal operation No GO to C10 C10 CHECK FOR A SHORTED FUNCTION SELECTOR SWITCH Connect Function Selector Switch C294c Measure the resistance between the A C cycling switch C130 4 circu...

Page 3067: ...tween the A C pressure cut off switch C1078 3 circuit 198 DG OG harness side and ground Is the resistance reading less than 10 000 ohms Yes GO to C14 No GO to C12 C12 CHECK THE A C CYCLING SWITCH FOR A SHORT TO GROUND Disconnect A C Cycling Switch C130 NOTE The A C pressure cut off switch C1078 for the 3 8L engine is shown C1078 for the 4 6L engines is similar The pin locations and the circuits ar...

Page 3068: ...ESSURE CUT OFF SWITCH Disconnect A C Pressure Cut off Switch C1078 Measure the resistance between the Rotunda EEC V Breakout Box pin 41 circuit 198 DG OG and ground Is the resistance less than 10 000 ohms Yes REPAIR circuit 198 DG OG for a short to ground TEST the system for normal operation No INSTALL a new A C pressure cut off switch REFER to Section 412 03 C15 CHECK THE FUNCTION SELECTOR SWITCH...

Page 3069: ...04 TEST the system for normal operation No REPAIR circuit 348 VT for an open TEST the system for normal operation C17 MEASURE THE VOLTAGE TO THE A C PRESSURE CUT OFF SWITCH Key in OFF position Connect A C Cycling Switch C130 Disconnect A C Pressure Cut off Switch C1078 Turn the function selector switch to the A C position NOTE The A C pressure cut off switch C1078 for the 3 8L engine is shown C107...

Page 3070: ...ystem for normal operation No REPAIR circuit 420 DB YE for an open TEST the system for normal operation C19 CHECK THE A C PRESSURE CUT OFF SWITCH Key in OFF position NOTE The A C pressure cut off switch C1078 for the 3 8L engine is shown C1078 for the 4 6L engines is similar The pin locations and the circuits are identical Measure the resistance between Rotunda Breakout Box pin 41 and A C high pre...

Page 3071: ...ey in ON position Measure the voltage at the CCRM C1262 13 circuit 20 WH LB harness side and ground Is the voltage reading greater than 10 volts Yes GO to C22 No REPAIR circuit 20 WH LB for an open TEST the system for normal operation C22 CHECK THE POWER TO THE A C CLUTCH Key in OFF position Connect CCRM 1262 Disconnect A C Clutch C100 Turn the function selector to the A C position Measure the vol...

Page 3072: ...rcuit 331 PK YE for an open TEST the system for normal operation C24 CHECK CIRCUIT 347 BK YE Key in OFF position Measure the resistance between CCRM C1262 23 circuit 347 BK YE harness side and A C clutch C100 1 harness side Is the resistance less than 5 ohms Yes GO to C25 No REPAIR circuit 347 BK YE for an open TEST the system for normal operation C25 CHECK CIRCUIT 347 BK YE FOR A SHORT TO GROUND ...

Page 3073: ... diagnostic tool PCM PID ACCS Does the PCM PID ACCS read ON Yes GO to D3 No GO to D5 D3 CHECK FOR A FALSE INPUT SIGNAL TO THE PCM Key in OFF position Disconnect PCM C175 Key in ON position Turn the function selector switch to the OFF position Measure the voltage between PCM C175 41 circuit 198 DG OG harness side and ground Is the voltage greater than 10 volts Yes GO to D4 No INSTALL a new powertra...

Page 3074: ...w constant control relay module TEST the system for normal operation No CHECK the clutch air gap REFER to Air Conditioning A C Clutch Air Gap Adjustment Test Step Result Action to Take E1 CHECK THE CENTER A C REGISTER DISCHARGE TEMPERATURE Carry out the refrigerant system tests Refer to Refrigerant System Tests in this section Use the recorded data from the refrigerant system tests to plot a verti...

Page 3075: ...n low pressure Is the intersection of the two lines within the upper and lower limits Yes GO to E4 No GO to E6 E4 CHECK FOR A SLOW OR CONTINUOUS RUN A C CLUTCH CYCLE RATE Use the recorded data from the refrigerant system tests to plot a vertical line for ambient temperature and a horizontal line for total A C clutch cycle time time ON plus time OFF in seconds Is the intersection of the two lines a...

Page 3076: ... to Section 412 03 TEST the system for normal operation E7 CHECK THE AMBIENT TEMPERATURE Refer to the data plot used to evaluate the system A C clutch OFF time in Step E5 Is the ambient temperature above 26 C 80 F Yes This is normal operation for the refrigerant system in high humidity conditions No DISCHARGE and RECOVER the system to correct an overcharge condition REFER to Air Conditioning A C S...

Page 3077: ...r normal operation E11 CHECK FOR A NORMAL SUCTION PRESSURE Use the recorded data from the refrigerant system tests to plot a vertical line for ambient temperature and a horizontal line for compressor suction low pressure Is the intersection of the two lines within the upper and lower limits Yes GO to E12 No GO to E15 E12 CHECK FOR A SLOW A C CLUTCH CYCLE RATE Use the recorded data from the refrige...

Page 3078: ...e system A C clutch OFF time performance in Step E13 Is the intersection of the two lines above the upper limit Yes INSTALL a new A C condenser core due to a partially restricted or plugged condition REFER to Section 412 03 TEST the system for normal operation No EVACUATE and RECHARGE the system when the intersection of the two lines is below the lower limit REFER to Air Conditioning A C System Re...

Page 3079: ...ure at the center panel vents Does the discharge air temperature vary Yes The temperature blend door is functioning correctly RETURN to the symptom chart No GO to F2 F2 CHECK FOR A BROKEN A C TEMPERATURE CONTROL CABLE Remove the climate control assembly to gain access to the control cable head Move the temperature control from full warm to full cold Inspect the cable control head as you move the t...

Page 3080: ... to Section 412 02 TEST the system for normal operation No GO to G3 G3 CHECK THE A C BLOWER MOTOR JUMPER WIRE Key in OFF position Disconnect Blower Motor Jumper C238 Key in ON position Check circuit 261 OG BK for an open between C2066 and C238 4 Is the resistance greater than 5 ohms Yes REPAIR circuit 261 OG BK TEST the system for normal operation No INSTALL a new blower motor REFER to Section 412...

Page 3081: ...ROUND Key in OFF position Measure the resistance between the jumper C238 3 circuit 261 OG BK and ground Is the resistance less than 5 ohms Yes GO to G7 No GO to G10 G7 CHECK CIRCUIT 261 OG BK FOR AN OPEN CIRCUIT Measure the resistance between the A C blower motor jumper C238 3 circuit 261 OG BK and the blower motor switch C294a 1 Yes REPAIR the blower motor jumper TEST the system for normal operat...

Page 3082: ...eration No GO to G9 G9 CHECK CIRCUIT 181 BN OG FOR VOLTAGE Measure the voltage between C294c 2 circuit 181 BN OG harness side and ground Is the voltage greater than 10 volts Yes INSTALL a new function selector switch REFER to Section 412 04 TEST the system for normal operation No REPAIR circuit 181 BN OG for an open TEST the system for normal operation G10 CHECK CIRCUIT 1205 BK FOR AN OPEN Yes INS...

Page 3083: ...F position GO to H4 H2 CHECK CIRCUIT 261 OG BK FOR A SHORT TO GROUND Key in OFF position Disconnect A C Blower Motor C2066 Disconnect Blower Motor Resistor C2185 Disconnect Blower Motor Switch C294a Measure the resistance between C2066 circuit 261 OG BK and ground Is the resistance greater than 10 000 ohms Yes GO to H3 No REPAIR circuit 261 OG BK for a short to ground TEST the system for normal op...

Page 3084: ...a new function selector switch REFER to Section 412 04 TEST the system for normal operation No REPAIR circuit 249 DB LG for a short to battery TEST the system for normal operation Test Step Result Action to Take I1 CHECK CIRCUIT 261 OG BK FOR AN OPEN CIRCUIT Key in OFF position Disconnect Blower Motor Switch C294a Key in ON position Turn the function selector switch to the FLOOR position Measure t...

Page 3085: ...t the blower motor switch to low Measure the voltage between the blower motor resistor C2185 4 circuit 261 OG BK jumper side and ground Is the voltage greater than 10 volts Yes GO to J2 No REPAIR circuit 261 OG BK for an open circuit between the blower motor and the blower motor resistor TEST the system for normal operation J2 CHECK CIRCUIT 1205 BK FOR AN OPEN Key in OFF position Measure the resis...

Page 3086: ...eater core CAUTION Spring type clamps are installed as original equipment Installation and overtightening of non specification clamps can cause leakage at the heater water hose connection and damage the heater core 2 Check the integrity of the heater water hose clamps Heater Core Plugged WARNING The heater core inlet hose will become too hot to handle if the system is working correctly 1 Check to ...

Page 3087: ...e into the heater core 7 Observe the pressure gauge for a minimum of three minutes 8 If the pressure drops check the heater water hose connections to the core tubes for leaks If the heater water hoses do not leak remove the heater core from the vehicle and carry out the bench test Heater Core Bench Test 1 Remove the heater core from the vehicle For additional information refer to Section 412 02 2 ...

Page 3088: ...uum pump 6 Open both gauge set valves and start the vacuum pump Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa 30 in Hg The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A C evaporator core or A C condenser core If the refrigerant is not completely removed from the oil outgassing will degrade ...

Page 3089: ...ings on the A C pressure test adapter 3 Attach the center hose of the manifold gauge set to a refrigerant container standing in an upright position 4 Hand rotate the compressor shaft 10 complete revolutions to distribute the oil inside the A C compressor 5 Open the low pressure gauge valve the high pressure gauge valve and the valve on the refrigerant container to allow the refrigerant vapor to fl...

Page 3090: ......

Page 3091: ...er to Refrigerant Identification Testing in this section If the refrigerant fails the analysis discontinue diagnosis and make recommendations for repairs If the refrigerant passes the analysis carry out the air conditioning system check 3 Air conditioning system check Connect manifold gauge set or charging station with gauges to refrigerant system With the vehicle in park parking brake set thermom...

Page 3092: ...UV or an electronic leak detector to check for leaks at all refrigerant lines connections and components After all tests have been completed report all findings and recommended repairs to your service advisor before carrying out further diagnostic procedures ...

Page 3093: ...t the special tool to the spring lock coupling 3 Push the tool into the cage opening to release the female fitting from the A C tube lock coupling spring 19E576 SECTION 412 00 Climate Control System General Information 2003 Mustang Workshop Manual Special Tool s Remover Refrigerant Coupling Set 412 039 T84L 19623 B ...

Page 3094: ... ring seal grooves resulting in refrigerant leaks Remove the O ring seals with a non metallic tool 6 CAUTION Do not use a screwdriver or similar tool to remove the A C tube lock coupling spring this can cause axial scratches across the O ring seal grooves resulting in refrigerant leaks Remove the A C tube lock coupling spring with a small hooked wire ...

Page 3095: ... to the tool 4 Coat the abrasive pad with PAG Refrigerant Compressor Oil R 134a Systems or equivalent 5 Roll the pad on the tool and install it in a variable speed drill motor 6 CAUTION Maintain low speed drill rotation when inserting or removing the cleaning Coupling Size Pad Size 3 8 inch 25 x 50 mm 1 x 2 inch 1 2 inch 25 x 50 mm 1 x 2 inch 5 8 inch 25 x 76 mm 1 x 3 inch 3 4 inch 25 x 102 mm 1 x...

Page 3096: ...oves or scratches If grooves and scratches are still present install a new component 9 Clean the O ring seal grooves with a 300 mm 12 inch length of natural fiber string Loop the string around the grooves and pull the string back and forth 10 Remove any foreign material from the grooves with a lint free cloth Connect 1 Install the A C tube lock coupling spring 2 Lubricate the inside of the couplin...

Page 3097: ...tent leakage during vehicle operation Install the O ring seals Lubricate the O ring seals with PAG Refrigerant Compressor Oil R 134a Systems or equivalent 4 Connect the spring lock coupling fittings with a twisting motion until the A C tube lock coupling spring snaps over the flared end of the female fitting 5 Install the A C tube lock coupling clip ...

Page 3098: ......

Page 3099: ... of the engine cooling system Depressurize the engine cooling system 2 Push the heater hose toward the tube to fully expose the locking tabs 3 NOTE When compressing the white coupling retainer with the special tool the special tool must be perpendicular to and on the highest point of the coupling NOTE If the heater hose coupling is accessible the retainer tabs can be compressed by hand to disconne...

Page 3100: ...moval Pull the heater hose away from the heater core tube 5 Spread the retainer tabs apart and slide the retainer off the tube Discard the retainer Connect 1 Clean the tubes and lubricate with coolant hose lubricant or plain water 2 Install a new coupling retainer 18D434 into the heater hose coupling housing ...

Page 3101: ...3 Push the heater hose coupling onto the tube 4 Make sure the heater hose coupling is fully engaged by lightly pulling on the heater hose ...

Page 3102: ...emove the nut from the peanut fitting 2 Pull the peanut fitting apart 3 CAUTION Do not use metal tools to remove the O ring seal They can cause axial scratches across the O ring seal groove resulting in refrigerant leaks Remove the O ring seal with a non metallic tool SECTION 412 00 Climate Control System General Information 2003 Mustang Workshop Manual ...

Page 3103: ... seal Lubricate the O ring seal with PAG Refrigerant Compressor Oil R 134a Systems F7AZ 19589 DA Motorcraft YN 12 C or equivalent meeting Ford specification WSH M1C231 B 3 Lubricate the inside of the fittings with PAG Refrigerant Compressor Oil R 134a Systems F7AZ 19589 DA Motorcraft YN 12 C or equivalent meeting Ford specification WSH M1C231 B 4 NOTE When correctly assembled the male and female f...

Page 3104: ......

Page 3105: ...bove normal idle speed Maintain the engine speed at 1 500 rpm 5 Determine the compressor discharge high pressure 1 Record the ambient temperature 2 Record the discharge high pressure 3 NOTE In ambient temperatures between 38 43 C 100 110 F the system performance pressures will be the same as those for ambient temperatures shown on the chart in the 32 38 C 90 100 F range The system performance is a...

Page 3106: ...ure reading falls between the upper and lower limits shown 7 Determine the A C clutch ON time 1 Record the ambient temperature 2 Record the A C clutch ON time in seconds 3 NOTE When the ambient temperature is above 26 C 80 F the A C clutch may not cycle The system performance is acceptable when the recorded time falls between the upper and lower limits shown 8 Determine the A C clutch OFF time 1 R...

Page 3107: ...ot cycle The system performance is acceptable when the recorded time falls between the upper and lower limits shown 10 Determine the A C clutch cycle rate per minute 1 Record the ambient temperature 2 Record the number of A C clutch cycles occurring in one minute 3 NOTE When the ambient temperature is above 26 C 80 F the A C clutch may not cycle The system performance is acceptable when the record...

Page 3108: ...n 38 43 C 100 110 F the A C register discharge temperatures will be the same as those for ambient temperatures shown on the chart in the 32 38 C 90 100 F range The system performance is acceptable when the center A C register discharge temperature falls between the upper and lower limits shown ...

Page 3109: ...ween the A C clutch hub 2884 and the A C clutch pulley 2E884 2 Remove the A C clutch Add or remove spacers between the A C clutch and the compressor shaft until clearance is within specification For additional information refer to Section 412 03 SECTION 412 00 Climate Control System General Information 2003 Mustang Workshop Manual ...

Page 3110: ...e center manifold and center hose 2 Remove the A C charging valve cap 19D702 from the low pressure service gauge port valve 3 Remove the A C charging valve cap from the high pressure service gauge port valve SECTION 412 00 Climate Control System General Information 2003 Mustang Workshop Manual Special Tool s R 134a Manifold Gauge Set 176 R032A or equivalent ...

Page 3111: ...pressure hose and the R 134a low side quick disconnect to the low pressure service gauge port valve 5 Connect the R 134a Manifold Gauge Set high pressure hose and the R 134a high side quick disconnect to the high pressure service gauge port valve ...

Page 3112: ......

Page 3113: ... air that might affect the leak detector 1 NOTE The system pressure should be between 413 551 kPa 60 80 psi at 24 C 75 F with the engine off Leak test the refrigerant system using the Refrigerant Leak Detector Follow the instructions included with the leak detector for handling and operation techniques 2 If a leak is found discharge and recover the refrigerant For additional information refer to A...

Page 3114: ......

Page 3115: ... always inspect each component 1 Check for leaks using a 120 Watt UV spot lamp Scan all components fittings and lines of the A C system 2 After the leak is repaired remove any traces of tracer dye with a general purpose oil solvent 3 Verify the repair by operating the system for a short time and inspect with the UV spot lamp SECTION 412 00 Climate Control System General Information 2003 Mustang Wo...

Page 3116: ......

Page 3117: ...l flushing agent Except for the hoses these components are typically discarded after A C system contamination Hoses can normally be reused unless they are clogged with foreign material The 3 785 liters 1 gallon of A C Systems Flushing Solvent F4AZ 19579 A and FL1 A filter used in A C Flush and Purge Machine 219 00022 are intended for use on one vehicle only They may be used to flush both the A C c...

Page 3118: ...rator core orifice mufflers or hoses Internal plumbing and material make up of these components make it impossible to correctly remove foreign material or residual flushing solvent 5 Use 3 785 liters one gallon of A C Systems Flushing Solvent part number F4AZ 19579 A to flush the heat exchanger for a minimum of 15 minutes The flush solvent may be used for one or both heat exchangers in the A C sys...

Page 3119: ......

Page 3120: ...g the refrigerant system you must verify the purity of the refrigerant For additional information refer to Refrigerant Identification Testing in this section 2 NOTE Some R 134a service centers require the use of an A C manifold gauge set For additional information refer to Manifold Gauge Set Connection in this section SECTION 412 00 Climate Control System General Information 2003 Mustang Workshop ...

Page 3121: ...d as close to 101 1 kPa 30 in Hg as possible Continue to operate the vacuum pump for a minimum of 45 minutes 3 Turn off the vacuum pump Observe the low pressure gauge for five minutes to make sure that the system vacuum is held If vacuum is not held for five minutes leak test the system service the leak and evacuate the system again Refrigerant System Charging NOTE Ford Motor Company recommends us...

Page 3122: ......

Page 3123: ...tion 412 03 4 Orient the filter inlet toward the A C condenser core 5 NOTE The pancake filter is not permanently installed and will be removed at the end of this procedure Temporarily install the pancake filter between the A C condenser core and the condenser to evaporator tube 1 Use flexible refrigerant hose of 17 238 kPa 2 500 psi burst rating 2 Make the connections using the A C Test Fitting Se...

Page 3124: ...t it idle briefly Make sure the A C system is operating correctly 10 Gradually bring the engine up to 1 200 rpm by running it at lower rpms for short periods first at 800 rpm then at 1 000 rpm Set the engine at 1 200 rpm and run it for one hour with the A C system operating 11 Stop the engine 12 Recover the refrigerant from the system For additional information refer to Air Conditioning A C System...

Page 3125: ...G Refrigerant Compressor Oil R 134a Systems or equivalent into the new A C compressor 2 For the suction accumulator drier drill one 13 mm 0 52 in hole in the suction accumulator drier cylinder and drain the oil into a calibrated container Add a quantity of new oil to match that drained from the old suction accumulator drier plus 60 ml 2 ounces of clean PAG Refrigerant Compressor Oil R 134a Systems...

Page 3126: ......

Page 3127: ...er and measure the volume for correct oil system matching For additional information refer to Refrigerant Oil Adding in this section 4 NOTE System flushing is the preferred method of cleaning However if flushing equipment is not available carry out system filtering Carry out an A C system flushing or filtering procedure If A C system flushing equipment is available clean the A C evaporator core an...

Page 3128: ......

Page 3129: ...weight concentrations of R 134a R 12 R 22 and hydrocarbons will also be displayed on the digital display 3 The percentage of air contained in the sample will be displayed if the R 134a or R 12 content is 98 or greater The diagnostic tool eliminates the effect of air when determining the refrigerant sample content because air is not considered a contaminant although air can affect A C system perfor...

Page 3130: ......

Page 3131: ... additional information refer to Refrigerant Oil Adding in this section The suction accumulator drier cannot be cleaned and a new suction accumulator drier must be installed Remove the suction accumulator drier For additional information refer to Section 412 03 4 Clean the A C evaporator core and the A C condenser core by flushing For additional information refer to Air Conditioning A C System Flu...

Page 3132: ......

Page 3133: ... tube hose ends in commercially available paint thinner containing methyl ethyl ketone MEK This solvent will seal the mini tube in the vacuum hose 5 Insert the ends of the mini tube vacuum hose approximately 9 mm 3 8 inch into the ends of the standard 1 8 inch repair vacuum hose section 6 Shake the repair joint after assembly to make sure the solvent is dispersed and the vacuum line is not plugged...

Page 3134: ......

Page 3135: ...01 Air Distribution and Filtering 2003 Mustang Workshop Manual Torque Specifications Description Nm lb in Steering column reinforcement 9 80 Instrument panel steering column cover bolts 9 80 Duct RH instrument panel register 9 80 ...

Page 3136: ...st nozzle when no vacuum is applied to any of the vacuum control motors This is done to prevent a situation where defrost cannot be obtained due to a system vacuum leak Air enters the passenger compartment from the instrument panel A C register 19893 heater outlet floor duct 18C433 windshield defroster hose nozzle 18490 side window demisters Passenger compartment air is exhausted from the vehicle ...

Page 3137: ...emister nozzle duct 2 18490 Defroster duct 3 19B680 A C evaporator register duct RH 4 19E630 RH demister nozzle duct 5 19893 A C evaporator register RH 6 19893 A C evaporator register center 7 18C433 Floor duct 8 18471 Heater air plenum chamber ...

Page 3138: ...9 19893 A C evaporator register LH ...

Page 3139: ...DIAGNOSIS AND TESTING Air Distribution For additional information refer to Section 412 00 SECTION 412 01 Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 3140: ...instrument panel steering column cover bolts 2 Unsnap and remove the instrument panel steering column cover 3 Remove the bolts and the steering column reinforcement 4 Remove the screws SECTION 412 01 Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 3141: ...5 Remove the register Installation 1 To install reverse the removal procedure ...

Page 3142: ......

Page 3143: ...er Removal and Installation NOTE The center register is incorporated into the instrument panel center finish panel For additional information refer to Section 501 12 SECTION 412 01 Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 3144: ...nstrument panel For additional information refer to Section 501 12 2 Remove the screws 3 Remove the hose and the nozzle from the instrument panel Installation 1 To install reverse the removal procedure SECTION 412 01 Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 3145: ...nstrument panel For additional information refer to Section 501 12 2 Remove the screws 3 Remove the hose and the nozzle from the instrument panel Installation 1 To install reverse the removal procedure SECTION 412 01 Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 3146: ...porator core housing For additional information refer to Section 412 02 2 Remove the screws and remove the heater outlet floor duct Installation 1 To install reverse the removal procedure SECTION 412 01 Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 3147: ...ve the instrument panel For additional information refer to Section 501 12 2 Remove the screws and remove the defroster duct Installation 1 To install reverse the removal procedure SECTION 412 01 Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 3148: ... Removal 1 Remove the instrument panel For additional information refer to Section 501 12 2 Remove the screws and remove the duct Installation 1 To install reverse the removal procedure SECTION 412 01 Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 3149: ......

Page 3150: ...ion 415 01 3 If equipped remove the CD player For additional information refer to Section 415 01 4 Remove the instrument panel center finish panel screws 5 Remove the instrument panel center finish panel screw 6 Unsnap and remove the instrument panel center finish panel 7 Remove the screws and remove the defroster duct SECTION 412 01 Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 3151: ...8 Remove the screw 9 Remove the screws and remove the plenum chamber Installation 1 To install reverse the removal procedure ...

Page 3152: ......

Page 3153: ...porator core housing For additional information refer to Section 412 02 2 Disconnect the vacuum line 3 Remove the screws and remove the duct Installation 1 To install reverse the removal procedure SECTION 412 01 Air Distribution and Filtering 2003 Mustang Workshop Manual ...

Page 3154: ......

Page 3155: ...p Manual General Specifications Item Specification Lubricant MERPOL ESE M99B144 B PAG Refrigerant Compressor Oil R 134a Systems F7AZ 19589 DA Motorcraft YN 12 C WSH M1C231 B Torque Specifications Description Nm lb in Interior evaporator core housing bracket nut and bolts 8 71 ...

Page 3156: ...rom just below the windshield during all system operations except for MAX A C cooling when recirculated air is used All airflow from the blower motor passes through the A C evaporator core 19860 The temperature is then regulated by reheating a portion of the air and blending it with the remaining cool air to the desired temperature The temperature blending is varied by the air temperature control ...

Page 3157: ...es NOTE The heater water hoses connect to the heater core using quick disconnect couplers The couplers are an integral part of the hose assemblies and cannot be separately serviced The heater water hoses 18472 provide a flexible connection between the engine and cooling system allowing hot water to travel from the engine to the heater core ...

Page 3158: ...DIAGNOSIS AND TESTING Heating and Defrosting Refer to Section 412 00 SECTION 412 02 Heating and Ventilation 2003 Mustang Workshop Manual ...

Page 3159: ...NSTALLATION Blower Motor Removal 1 Disconnect the jumper wire 2 Disconnect the main harness 3 Remove the screws 4 Separate the cover from the motor SECTION 412 02 Heating and Ventilation 2003 Mustang Workshop Manual ...

Page 3160: ...5 Separate the motor from the housing 6 Disconnect the jumper from the motor Remove the blower motor Installation 1 To install reverse the removal procedure ...

Page 3161: ......

Page 3162: ...ing system For additional information refer to Section 303 03A or Section 303 03B 4 Remove the instrument panel For additional information refer to Section 501 12 5 Disconnect the heater hose couplings from the heater core For additional information refer to Section 412 00 6 Disconnect the vacuum connector SECTION 412 02 Heating and Ventilation 2003 Mustang Workshop Manual Material Item Specificat...

Page 3163: ...suction accumulator drier For additional information refer to Section 412 03 8 Disconnect the A C liquid line Discard the O ring seals 9 Remove the evaporator core housing nuts 10 Remove the nut 11 Remove the screw ...

Page 3164: ...ousing bolts 13 Remove the evaporator core housing Installation 1 To install reverse the removal procedure Lubricate the coolant hoses with coolant hose lubricant or plain water only if needed Install new O ring seals lubricated with PAG oil ...

Page 3165: ......

Page 3166: ... evaporator core housing For additional information refer to Evaporator Core Housing in this section 2 Remove the foam weather seal 3 Remove the screws and remove the heater core cover 4 Remove the heater core Installation 1 NOTE Be sure to install a new oval foam weather seal around the heater core inlet and outlet tubes To install reverse the removal procedure SECTION 412 02 Heating and Ventilat...

Page 3167: ......

Page 3168: ...r to Evaporator Core Housing in this section 2 Remove the foam weather seal 3 Remove the screws and remove the heater core 4 Remove the screws and remove the A C recirculating air duct 5 Remove the vacuum reservoir 1 Disconnect the vacuum line 2 Remove the screw SECTION 412 02 Heating and Ventilation 2003 Mustang Workshop Manual ...

Page 3169: ...eater air damper door motor 1 Disconnect the vacuum lines 2 Loosen the nuts and unclip the motor 7 Release the vacuum harness from the housing 8 Remove the screws and remove the resistor 9 Disconnect the jumper wire ...

Page 3170: ...10 Disconnect the main harness 11 Remove the screws 12 Remove the blower motor 13 Remove the screws and remove the duct 14 Remove the mounting brackets ...

Page 3171: ...Assembly 1 To assemble reverse the disassembly procedure ...

Page 3172: ...s Description Nm lb ft lb in A C compressor mounting bolts 25 18 A C manifold retaining bolt 20 15 3 8L engine A C compressor mounting bracket bolts 47 35 3 8L engine A C compressor mounting bracket nut 25 18 A C compressor clutch retaining bolt 13 10 Suction accumulator drier clamp screw 8 71 Coolant bottle bolts 10 89 Peanut fittings 8 71 Radiator bracket bolts 9 81 Condenser core bracket bolts ...

Page 3173: ......

Page 3174: ...cling switch senses A C evaporator core pressure to control A C compressor operation An A C compressor pressure relief valve is installed in the A C manifold and tube 19D734 to protect the refrigerant system against excessively high refrigerant pressures An evaporator core orifice is installed in the A C evaporator core inlet tube to meter the liquid refrigerant into the A C evaporator core A refr...

Page 3175: ...e design utilizing the tangential design mount Item Part Number Description 1 19E561 A C cycling switch 2 19D701 A C charge port valve low side 3 19D594 Refrigerant containment switch 3 8L vehicles 3 19D594 Dual function pressure switch 4 6L vehicles 4 19D734 A C manifold and tube 5 19D644 A C compressor pressure relief valve 6 19703 A C compressor 7 19D701 A C charge port valve high side 8 19712 ...

Page 3176: ...oil viscosity This is normal for the A C compressor and is caused by break in wear of the piston rings The magnetic A C clutch has the following characteristics It drives the compressor shaft When the battery positive voltage B is applied to the A C clutch field coil the clutch plate and hub assembly is drawn toward the A C clutch pulley The magnetic force locks the clutch plate and hub assembly a...

Page 3177: ...over fins and tubes to extract heat and by condensing gas to liquid refrigerant as it is cooled Refrigerant Lines The condenser to evaporator tube 19835 contains the high pressure liquid refrigerant upstream of the evaporator core orifice The A C manifold and tube 19D734 is attached to the A C compressor is sealed with O ring seals and has the following features The upstream side contains low pres...

Page 3178: ...C evaporator core outlet tube This flow pattern accelerates the flow of refrigerant and oil through the A C evaporator core Evaporator Core Orifice NOTE The evaporator core orifice is an integral part of the condenser to evaporator line and should be installed as an assembly with the line NOTE A new evaporator core orifice should be installed whenever a new A C compressor is installed The evaporat...

Page 3179: ... The suction accumulator is perforated The refrigerant system has been opened to the atmosphere for a period of time longer than required to make a minor repair There is evidence of moisture in the system such as internal corrosion of metal refrigerant lines or the refrigerant oil is thick and dark Item Part Number Description 1 19E561 A C cycling switch 2 O ring seal part of 19C836 3 19D701 Low p...

Page 3180: ... may be in the refrigerant system A fitting located on the top of the suction accumulator is used to attach the A C cycling switch A long travel Schrader type valve stem core is installed in the fitting so that the A C cycling switch can be removed without discharging the A C system A C Cycling Switch The A C cycling switch is mounted on a Schrader type valve fitting on the top of the suction accu...

Page 3181: ...engage the high speed fan control When the pressure drops the contacts open and the high speed fan control is disengaged Refrigerant Containment Switch 3 8L The refrigerant containment switch is used to interrupt A C compressor operation in the event of high system discharge pressures The refrigerant containment switch is mounted on a Schrader type valve fitting on the high pressure side of the co...

Page 3182: ...cted Once the coupling is connected the indicator ring is no longer necessary but will remain captive by the coupling near the cage opening The indicator ring may also be used during repair operations to indicate connection of the coupling An A C tube lock coupling clip 19E746 may be used to secure the coupling but is not required Service Gauge Port Valves The high pressure service gauge port valv...

Page 3183: ...e required for both the high side and low side service gauge ports A new Schrader type valve core can be installed if the seal leaks Always install the A C charging valve cap 19D702 on the service gauge port valves after repairing the refrigerant system 19D734 6 19D702 A C charging valve cap ...

Page 3184: ...DIAGNOSIS AND TESTING Air Conditioning Refer to Section 412 00 SECTION 412 03 Air Conditioning 2003 Mustang Workshop Manual ...

Page 3185: ...o Section 412 00 Install a new evaporator core orifice 19D990 as directed by the A C flushing or filtering procedure Install a new suction accumulator 19C836 as directed by the A C flushing or filtering procedure NOTE Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A C ...

Page 3186: ...n the clamp 2 Disconnect the crankcase ventilation tube 6758 3 Remove the air cleaner outlet tube assembly 6 Remove the drive belt 8620 from the A C compressor pulley 7 Disconnect the electrical compressor clutch connector 8 Remove the bolt and disconnect the A C manifold and tube 19D734 Discard the O ring seals ...

Page 3187: ...ng of the refrigerant system is not to be performed lubricate the refrigerant system with the correct amount of clean PAG oil For additional information refer to Section 412 00 11 If filtering of the air conditioning system is not to be performed evacuate leak test and charge the refrigerant system For additional information refer to Section 412 00 ...

Page 3188: ......

Page 3189: ...tor core orifice 19D990 as directed by the A C flushing or filtering procedure Install a new suction accumulator 19C836 as directed by the A C flushing or filtering procedure NOTE Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A C compressor or damage to the suction ac...

Page 3190: ... seals lubricated in clean PAG oil If filtering of the refrigerant system is not to be performed lubricate the refrigerant system with the correct amount of clean PAG oil For additional information refer to Section 412 00 8 If filtering of the refrigerant system is not to be performed evacuate leak test and charge the refrigerant system For additional information refer to Section 412 00 ...

Page 3191: ......

Page 3192: ...ve the A C compressor 19703 For additional information refer to Air Conditioning A C Compressor 3 8L in this section 2 Remove the three bolts and one nut 3 Remove the A C compressor mounting bracket 4 To install reverse the removal procedure SECTION 412 03 Air Conditioning 2003 Mustang Workshop Manual ...

Page 3193: ...L or equivalent Installer A C Compressor Coil 412 065 T89P 19623 EH Holding Fixture Compressor Clutch 3 8L vehicles 412 098 T94P 19703 AH Holding Fixture Compressor Clutch 4 6L vehicles 412 103 T95L 19703 AH Remover Differential Bearing 205 116 T77F 4220 B1 Installer A C Compressor Field Coil 412 078 T91L 19623 CH Remover A C Compressor Field Coil 412 067 T89P 19623 FH ...

Page 3194: ... C disc and hub assembly 19D786 with the special tool 2 Remove the bolt 3 Remove the A C disc and hub assembly and the A C clutch hub spacer 19D648 1 Thread an 8 x 1 25 mm bolt into the A C clutch to force it from the compressor shaft 2 Lift the A C disc and hub assembly and the A C clutch hub spacer from the compressor shaft 4 Remove the pulley snap ring 5 Remove the A C clutch pulley 2E884 ...

Page 3195: ...ve the A C clutch field coil Installation 1 Clean the A C disc and field coil and pulley mounting surfaces 2 CAUTION Do not use air tools The A C clutch field coil can be easily damaged Install the A C clutch field coil 1 Place the A C clutch field coil on the A C compressor with the A C clutch field coil electrical connector correctly positioned 2 Using the special tools install the A C field coi...

Page 3196: ...ng installation Install the A C clutch pulley 4 Install the pulley snap ring with the bevel side out 5 Place one nominal thickness A C clutch hub spacer inside the clutch hub spline opening 6 Install the A C clutch ...

Page 3197: ...bly retaining bolt 8 Measure and adjust the clutch air gap by removing or adding A C clutch hub spacers 9 Install the A C compressor For additional information refer to Air Conditioning A C Compressor 3 8L or Air Conditioning A C Compressor 4 6L in this section ...

Page 3198: ...hicles 412 098 T94P 19703 AH Holding Fixture Compressor Clutch 4 6L vehicles 412 103 T95L 19703 AH Protector A C Compressor Shaft Oil Seal 412 061 T89P 19623 CH Remover A C Compressor Shaft Oil Seal 412 059 T89P 19623 BH Installer A C Compressor Shaft Oil Seal 412 058 T89P 19623 AH Remover A C Compressor Snap Ring 412 063 T89P 19623 DH Remover O ring Seal 100 010 T71P 19703 C Material ...

Page 3199: ...bolt 3 Remove the A C disc and hub assembly and spacer 19D648 1 Thread an 8 x 1 25 mm 0 05 in bolt into the A C disc and hub assembly to force it from the compressor shaft 2 Lift the A C disc and hub assembly and spacer from the compressor shaft 4 Using the special tool remove the shaft seal felt from the nose of the A C compressor 5 Clean the compressor nose area Item Specification PAG Refrigeran...

Page 3200: ...ial tool to position the tool tip and the snap ring eye closest to the A C compressor shaft 8 Pull the special tool up quickly while keeping the tool shaft against the side of the nose opening and remove the snap ring 9 Engage the special tool into the inside diameter of the shaft seal ...

Page 3201: ...To prevent refrigerant system contamination do not allow dirt or other foreign materials to enter the A C compressor Clean the A C compressor nose area 2 Place the shaft seal on the special tool Lubricate the shaft seal and the special tool with PAG oil or equivalent 3 Position the shaft seal and the special tool over the A C compressor shaft ...

Page 3202: ... A C compressor shaft until seated 5 Install the shaft seal snap ring 6 Carry out the A C compressor external leak test For additional information refer to Component Tests in Section 412 00 7 Install the shaft seal felt 8 Install the A C clutch hub spacer ...

Page 3203: ...A C disc and hub assembly retaining bolt 11 Measure and adjust the clutch air gap by removing or adding spacers as needed 12 Install the A C compressor For additional information refer to Air Conditioning A C Compressor 3 8L or Air Conditioning A C Compressor 4 6L in this section ...

Page 3204: ......

Page 3205: ...A C compressor or damage to the suction accumulator NOTE If an evaporator core leak is suspected the evaporator core must be leak tested before it is removed from the vehicle For additional information refer to Section 412 00 1 Remove the evaporator core housing For additional information refer to Section 412 02 2 Transfer the components from the old evaporator core housing to the new evaporator c...

Page 3206: ... 00 2 Disconnect the A C cycling switch electrical connector 3 Remove the cycling switch 4 Disconnect the suction line spring lock coupling Discard the O ring seals SECTION 412 03 Air Conditioning 2003 Mustang Workshop Manual Material Item Specification PAG Refrigerant Compressor Oil R 134a Systems F7AZ 19589 DA Motorcraft YN 12 C WSH M1C231 B ...

Page 3207: ...nut 6 Disconnect the suction accumulator from the evaporator outlet Discard the O ring seals 7 Remove the suction accumulator 8 To install reverse the removal procedure Install new O ring seals lubricated in clean PAG oil ...

Page 3208: ...refrigerant system with the correct amount of clean PAG oil For additional information refer to Section 412 00 9 Evacuate leak test and charge the refrigerant system For additional information refer to Section 412 00 ...

Page 3209: ... breather 3 Disconnect the mass air flow MAF sensor electrical connector 4 Remove the air cleaner outlet tube 1 Loosen the clamp 2 Disconnect the crankcase ventilation tube 3 Remove the air cleaner outlet tube SECTION 412 03 Air Conditioning 2003 Mustang Workshop Manual Material Item Specification PAG Refrigerant Compressor Oil R 134a Systems F7AZ 19589 DA Motorcraft YN 12 C WSH M1C231 B ...

Page 3210: ...relief valve Discard the O ring seal 6 To install reverse the removal procedure Install a new O ring seal lubricated in clean PAG oil 7 Evacuate leak test and charge the refrigerant system For additional information refer to Section 412 00 ...

Page 3211: ...ccumulator 1 Recover the refrigerant For additional information refer to Section 412 00 2 Raise the vehicle For additional information refer to Section 100 02 3 Remove the A C compressor pressure relief valve 19D644 Discard the O ring seal 4 To install reverse the removal procedure Install a new O ring seal lubricated in clean PAG oil SECTION 412 03 Air Conditioning 2003 Mustang Workshop Manual Ma...

Page 3212: ......

Page 3213: ...ation from a failed A C compressor or damage to the suction accumulator All vehicles 1 Recover the refrigerant For additional information refer to Section 412 00 2 Remove the pin type retainers and remove the upper radiator sight shield 3 Remove the air cleaner and air cleaner outlet tube For additional information refer to Section 303 12 4 6L 2V 4 6L 4V vehicles 4 Remove the bolts and position th...

Page 3214: ...4 6L 4V vehicles 5 Remove the bolts and position the coolant bottle aside 3 8L vehicles 6 Remove the bolts 7 Remove the bracket and the coolant bottle ...

Page 3215: ...s Vehicles with 4WABS 9 Remove the hydraulic control unit upper bracket bolts 10 Raise the vehicle 11 Remove the hydraulic control unit lower bracket bolt and position the hydraulic control unit aside 12 Lower the vehicle All vehicles 13 Remove the bolts and the radiator brackets ...

Page 3216: ...14 Position the radiator rearward 15 Remove the pin type retainers 16 Position the wiring harness rearward 17 Remove the condenser bolts ...

Page 3217: ...ll new O ring seals lubricated in clean PAG oil Lubricate the refrigerant system with the correct amount of clean PAG oil For additional information refer to Section 412 00 20 Evacuate leak test and charge the refrigerant system For additional information refer to Section 412 00 ...

Page 3218: ...uction accumulator 1 Recover the refrigerant For additional information refer to Section 412 00 2 Unlatch the air breather 3 Disconnect the mass air flow MAF sensor electrical connector 4 Remove the air cleaner outlet tube 1 Loosen the clamp 2 Disconnect the crankcase ventilation tube 3 Remove the air cleaner outlet tube SECTION 412 03 Air Conditioning 2003 Mustang Workshop Manual Material Item Sp...

Page 3219: ...ect the refrigerant containment switch RCS electrical connector 6 Remove the RCS 7 Remove the nut and disconnect A C fitting Discard the O ring seal 8 Disconnect the spring lock coupling Discard the O ring seals ...

Page 3220: ... the removal procedure Install new O ring seals lubricated in clean PAG oil Lubricate the refrigerant system with the correct amount of clean PAG oil For additional information refer to Section 412 00 12 Evacuate leak test and charge the refrigerant system For additional information refer to Section 412 00 ...

Page 3221: ......

Page 3222: ...pressor or damage to the suction accumulator 1 Recover the refrigerant For additional information refer to Section 412 00 2 Disconnect the suction line spring lock coupling Discard the O ring seals 3 Remove the A C muffler bracket nut 4 Disconnect the spring lock coupling Discard the O ring seals SECTION 412 03 Air Conditioning 2003 Mustang Workshop Manual Material Item Specification PAG Refrigera...

Page 3223: ...O ring seals 7 To install reverse the removal procedure Install new O ring seals lubricated in clean PAG oil Lubricate the refrigerant system with the correct amount of clean PAG oil For additional information refer to Section 412 00 8 Evacuate leak test and charge the refrigerant system For additional information refer to Section 412 00 ...

Page 3224: ......

Page 3225: ...or additional information refer to Section 412 00 2 Remove the air cleaner outlet tube For additional information refer to Section 303 12 3 Disconnect the spring lock coupling at the suction accumulator Discard the O ring seals 4 Disconnect the spring lock coupling at the compressor manifold Discard the O ring seals 5 Remove the suction accumulator to compressor line SECTION 412 03 Air Conditionin...

Page 3226: ...seals lubricated in clean PAG oil Lubricate the refrigerant system with the correct amount of clean PAG oil For additional information refer to Section 412 00 7 Evacuate leak test and charge the refrigerant system For additional information refer to Section 412 00 ...

Page 3227: ...or damage to the suction accumulator 1 Recover the refrigerant For additional information refer to Section 412 00 2 Disconnect the dual function pressure switch electrical connector and remove the switch 3 Remove the A C muffler bracket nut 4 Disconnect the fitting at the condenser Discard the O ring seal SECTION 412 03 Air Conditioning 2003 Mustang Workshop Manual Material Item Specification PAG ...

Page 3228: ... reverse the removal procedure Install new O ring seals lubricated in clean PAG oil For additional information refer to Section 412 00 Lubricate the refrigerant system with the correct amount of clean PAG oil For additional information refer to Section 412 00 8 Evacuate leak test and charge the refrigerant system For additional information refer to Section 412 00 ...

Page 3229: ......

Page 3230: ...r additional information refer to Section 412 00 2 Remove the air cleaner outlet tube For additional information refer to Section 303 12 3 Raise the vehicle For additional information refer to Section 100 02 4 Remove the line bracket pin type retainer 5 Lower the vehicle 6 Remove the nut and disconnect the fitting at the condenser Discard the O ring seal SECTION 412 03 Air Conditioning 2003 Mustan...

Page 3231: ... 9 To install reverse the removal procedure Install new O ring seals lubricated in clean PAG oil Lubricate the refrigerant system with the correct amount of clean PAG oil For additional information refer to Section 412 00 10 Evacuate leak test and charge the refrigerant system For additional information refer to Section 412 00 ...

Page 3232: ......

Page 3233: ... cooling and air distribution The temperature blend control setting determines air temperature The manual climate control components are used to select air inlet source outside or recirculated select blower motor speed select discharge air temperature temperature blend select discharge air location defrost panel floor select A C compressor clutch operation Component Locations SECTION 412 04 Contro...

Page 3234: ... selection is accomplished with a manually controlled blend door actuator that controls positioning of the temperature blend door Movement of the control knob 18519 from Item Part Number Description 1 18A318 Vacuum control motor panel defrost door 2 19988 Temperature blend door actuator cable 3 18A318 Vacuum control motor air inlet door 4 A C vacuum reservoir tank and bracket part of 18454 5 18A31...

Page 3235: ...rature reaches 105 110 C 221 230 F interrupting the blower motor operation in all speeds except HI The thermal limiter cannot be reset and is not serviceable Control Actuators Temperature Control Cable The temperature control cable 19988 has the following features The cable assembly has a constant tension pull pull dual cable design The pull pull design allows for constant smooth communication bet...

Page 3236: ...Shaft fully retracted with vacuum applied to both ports ...

Page 3237: ...DIAGNOSIS AND TESTING Control Components Refer to Section 412 00 SECTION 412 04 Control Components 2003 Mustang Workshop Manual ...

Page 3238: ...l information refer to Section 412 01 2 Remove the screws 3 Disconnect the connectors 4 Using the special tool disconnect the temperature control cable from the control head SECTION 412 04 Control Components 2003 Mustang Workshop Manual Special Tool s Remover Heater Control Cable Retainer 412 088 T94P 18532 A ...

Page 3239: ...uts and disconnect the vacuum connector Installation 1 Align the blend door driver to the full heat position 2 Place the temperature control knob in the full WARM position 3 Attach the cable drive to the control head ...

Page 3240: ...4 Rotate the knob back and forth from full WARM to full COOL 5 Check the cable control for correct range of movement 6 Connect the electrical connectors 7 Install the vacuum connector and nuts ...

Page 3241: ...8 Install the control head 9 Install the center instrument panel register For additional information refer to Section 412 01 ...

Page 3242: ...ditional information refer to Control Assembly in this section 2 NOTE All three switches are removed the same Remove the knob 3 Remove the screw 4 Rotate the switch and remove it from the control head assembly Installation SECTION 412 04 Control Components 2003 Mustang Workshop Manual ...

Page 3243: ...1 To install reverse the removal procedure ...

Page 3244: ...emoval 1 Remove the control assembly For additional information refer to Control Assembly in this section 2 Unsnap and remove the drive assembly Installation 1 To install reverse the removal procedure SECTION 412 04 Control Components 2003 Mustang Workshop Manual ...

Page 3245: ...STALLATION Resistor Removal 1 Disconnect the connector 2 Remove the screws 3 Remove the resistor Installation 1 To install reverse the removal procedure SECTION 412 04 Control Components 2003 Mustang Workshop Manual ...

Page 3246: ......

Page 3247: ...rument panel For additional information refer to Section 501 12 2 Disconnect the vacuum hose 3 Disconnect the control arm 4 Remove the vacuum control motor Remove the screws Installation 1 To install reverse the removal procedure SECTION 412 04 Control Components 2003 Mustang Workshop Manual ...

Page 3248: ......

Page 3249: ...trument panel For additional information refer to Section 501 12 2 Disconnect the vacuum hose 3 Remove the vacuum control motor 1 Remove the steel clip 2 Loosen the nuts Installation 1 To install reverse the removal procedure SECTION 412 04 Control Components 2003 Mustang Workshop Manual ...

Page 3250: ... instrument panel For additional information refer to Section 501 12 2 Unclip the control arm 3 Remove the vacuum control motor 1 Disconnect the vacuum lines 2 Loosen the nuts Installation 1 To install reverse the removal procedure SECTION 412 04 Control Components 2003 Mustang Workshop Manual ...

Page 3251: ... Access the vacuum reservoir tank through the glove compartment 2 Remove the reservoir 1 Disconnect the vacuum connector 2 Remove the screw Installation 1 To install reverse the removal procedure SECTION 412 04 Control Components 2003 Mustang Workshop Manual ...

Page 3252: ...id electronic cluster HEC which uses both hardwired circuitry and the standard corporate protocol SCP communication network to transmit and receive information The Mustang instrument cluster backlighting has illumination bulbs that are installed separately from the instrument cluster The Cobra instrument cluster has a laminated electroluminescent applique to backlight the cluster The electrolumine...

Page 3253: ...s not visually evident determine the symptom and proceed to the Symptom Chart Symptom Chart SECTION 413 00 Instrument Cluster and Panel Illumination 2003 Mustang Workshop Manual Special Tool s 73III Automotive Meter 105 R0057 or equivalent Visual Inspection Chart Electrical Central junction box CJB fuses 5 15A 21 5A 34 20A 37 5A 32 15A 27 20A Circuitry Damaged switch Symptom Chart Condition Possib...

Page 3254: ...dlamp switch components test Refer to Wiring Diagrams Cell 149 for schematic and connector information Is the headlamp switch OK Yes RECONNECT the headlamp switch GO to A3 No INSTALL a new headlamp switch REFER to Section 417 01 TEST the system for normal operation A3 CHECK CIRCUIT 1045 DB WH Place the headlamp switch in the ON position Rotate the instrument panel dimmer switch to the full illumin...

Page 3255: ... resistances less than 5 ohms Yes INSTALL a new instrument cluster REFER to Section 413 01 TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation Test Step Result Action to Take C1 CHECK VOLTAGE TO CLIMATE CONTROL ILLUMINATION Disconnect Function Selector Switch C294b Place the headlamp switch in the ON position Rotate the instrument panel dimmer switch to ...

Page 3256: ...n the ON position Rotate the instrument panel dimmer switch to the full illumination position Measure the voltage between the audio unit C290a pin 1 circuit 19 LB RD harness side and ground Is the voltage greater than 10 volts Yes GO to D2 No REPAIR the circuit TEST the system for normal operation D2 CHECK GROUND TO AUDIO UNIT Measure the resistance between the audio unit C290a pin 2 circuit 1205 ...

Page 3257: ... voltage between the inoperative illumination source circuit 19 LB RD harness side and ground Is the voltage greater than 10 volts Yes GO to E2 No REPAIR the circuit TEST the system for normal operation E2 CHECK SINGLE ILLUMINATION SOURCE GROUND Measure the resistance between inoperative illumination source circuit 1205 BK harness side and ground Is the resistance less than 5 ohms Yes INSTALL a ne...

Page 3258: ...l information refer to Section 413 01 2 Remove the necessary instrument cluster bulbs by rotating the bulb one quarter turn counterclockwise and lifting straight out of the instrument cluster 3 To install reverse the removal procedure SECTION 413 00 Instrument Cluster and Panel Illumination 2003 Mustang Workshop Manual ...

Page 3259: ...op Manual Item Part Number Description 1 Fuel gauge 2 Engine coolant temperature gauge 3 Speedometer 4 Turn signal hazard indicator 5 High beam indicator 6 Tachometer 7 Odometer 8 Trip odometer reset button 9 Voltmeter gauge 10 Oil pressure gauge 11 CHECK FUEL CAP indicator 12 BRAKE warning indicator 13 ABS warning indicator 14 Traction control indicator 15 Overdrive off O D OFF indicator automati...

Page 3260: ...ng system indicator 21 Safety belt warning indicator Item Part Number Description 1 Fuel gauge 2 Engine coolant temperature gauge 3 Speedometer 4 Turn signal hazard indicator 5 High beam indicator 6 Tachometer 7 Odometer 8 Trip odometer reset button 9 Voltmeter gauge 10 Oil pressure gauge 11 CHECK FUEL CAP indicator 12 BRAKE warning indicator 13 ABS warning indicator ...

Page 3261: ...dicator 19 AIR BAG warning indicator 20 Charging system indicator 21 Safety belt warning indicator Item Part Number Description 1 Fuel gauge 2 Engine coolant temperature gauge 3 Speedometer 4 Turn signal hazard indicator 5 High beam indicator 6 Tachometer 7 Odometer 8 Trip odometer reset button 9 Boost gauge 10 Oil pressure gauge 11 CHECK FUEL CAP indicator 12 BRAKE warning indicator ...

Page 3262: ...rol indicator 15 Overdrive off O D OFF indicator automatic transmission 16 LOW FUEL level indicator 17 SERVICE ENGINE SOON indicator 18 THEFT indicator 19 AIR BAG warning indicator 20 Charging system indicator 21 Safety belt warning indicator ...

Page 3263: ... or command message does the module which received the input control the output of the feature or does it output a message over the SCP network to another module which module controls the output of the feature The instrument cluster carries out a display prove out to verify that the warning indicator miniature bulbs for monitored systems are functioning correctly When the ignition switch is in the...

Page 3264: ... the instrument cluster fails to receive the odometer message for more than two seconds the odometer will display dashes Fuel Gauge The fuel sender is hardwired to the fuel gauge When the instrument cluster fails to receive the fuel level signal for more than 33 seconds the fuel level gauge will move below E empty If the fuel level signal operates correctly for more than 33 seconds the fuel gauge ...

Page 3265: ...ing Indicator The BRAKE warning indicator activates when the generic electronic module GEM detects the ignition switch circuits are in the RUN state when the GEM detects low brake fluid level or that the parking brake is applied The BRAKE warning indicator will prove out starting when the GEM detects that the ignition circuits have made a transition to RUN or START from OFF ACC or keyout and endin...

Page 3266: ...nt cluster does not provide a prove out for the O D OFF indicator but will remain illuminated if the overdrive has been commanded off following the instrument cluster prove out Traction Control Indicator During initialization the instrument cluster will receive the traction control system state status message from the traction control module to determine if the vehicle is equipped with traction co...

Page 3267: ...out the self test diagnostics for the instrument cluster or the GEM 7 If the DTCs retrieved are related to the concern go to the Instrument Cluster Diagnostic Trouble Code DTC Index or the GEM Diagnostic Trouble Code Index to continue diagnostics 8 If no DTCs related to the concern are retrieved proceed to the Symptom Chart to continue diagnostics Instrument Cluster Self Diagnostic Mode To enter t...

Page 3268: ... 0 if input is not received if input received is invalid for one second or more or if speed is 0 tAc Displays the tachometer data received from the PCM via the SCP network within tolerances Tachometer will indicate present rpm Display will show 0 if input is not received if input received is invalid for one second or more or if engine rpm is 0 FUEL Displays the code 0 255 for the fuel sender input...

Page 3269: ...iagnostic Mode Displayed DTC Description Source Action B1202 9202 Fuel Sender Open Circuit Instrument Cluster Go To Pinpoint Test B B1204 9204 Fuel Sender Short to Ground Instrument Cluster Go To Pinpoint Test B B1317 9317 Battery Voltage High Instrument Cluster Section 414 00 B1318 9318 Battery Voltage Low Instrument Cluster Section 414 00 B1342 9342 ECU is Defective Instrument Cluster INSTALL a ...

Page 3270: ...ition Key In Circuit Open GEM REFER to Section 413 09 B1359 Ignition Run Acc Circuit Failure GEM REFER to Section 211 05 B1396 Power Door Lock Circuit Short to Battery GEM REFER to Section 501 14B B1397 Power Door Unlock Circuit Short to Battery GEM REFER to Section 501 14B B1405 Driver Power Window Down Circuit Short to Battery GEM REFER to Section 501 11 B1408 Driver Power Window Up Circuit Shor...

Page 3271: ...High Speed Circuit Motor Failure GEM REFER to Section 501 16 B1551 Decklid Release Circuit Failure GEM REFER to Section 501 14B B1553 Decklid Release Circuit Short to Battery GEM REFER to Section 501 14B B1555 Ignition Run Start Circuit Failure GEM REFER to Section 211 05 B1687 Lamp Dome Input Circuit Short to Battery GEM REFER to Section 417 02 B2486 Parklamp Output Relay Driver Circuit Failure G...

Page 3272: ...n Circuitry Engine oil pressure switch Instrument cluster Go To Pinpoint Test C Incorrect temperature gauge indication Circuitry Engine coolant temperature sensor Powertrain control module PCM Instrument cluster Go To Pinpoint Test D Incorrect voltage gauge indication except Cobra Circuitry Generator Standard corporate protocol SCP network Instrument cluster Go To Pinpoint Test E Incorrect tachome...

Page 3273: ... Test I The odometer is inoperative Circuitry Powertrain control module PCM Instrument cluster Go To Pinpoint Test J The safety belt warning indicator is inoperative chime is operative does not operate correctly Circuitry Generic electronic module GEM Instrument cluster Go To Pinpoint Test K Inaccurate speedometer reading Instrument cluster Powertrain control module PCM Go To Pinpoint Test L The O...

Page 3274: ...O The charging system warning indicator is never always on Circuitry Generator Charging system warning indicator bulb Instrument cluster Go To Pinpoint Test P The high beam indicator is never always on Circuitry High beam indicator bulb Instrument cluster Go To Pinpoint Test Q The air bag warning indicator is never always on Circuitry Air bag warning indicator bulb Instrument cluster Restraint con...

Page 3275: ...dicator is never always on Circuitry THEFT indicator LED Instrument cluster REFER to Section 419 01 The traction control indicator is never always on Circuitry Traction control switch Standard corporate protocol SCP network Powertrain control module PCM ABS module Instrument cluster Go To Pinpoint Test U The integrated circuit display is inoperative erratic Instrument cluster Go To Pinpoint Test V...

Page 3276: ... operation A2 CHECK THE RUN POWER SUPPLY TO THE INSTRUMENT CLUSTER Key in ON position Measure the voltage between the instrument cluster C220b pin 11 circuit 489 PK BK harness side and ground Is the voltage greater than 10 volts Yes GO to A3 No REPAIR the circuit TEST the system for normal operation A3 CHECK THE RUN START POWER SUPPLY TO THE INSTRUMENT CLUSTER Key in OFF position Disconnect Instru...

Page 3277: ...ake B1 CARRY OUT THE INSTRUMENT CLUSTER FUEL GAUGE ACTIVE COMMAND CAUTION Use the correct probe adapter s when making measurements Failure to use the correct probe adapter s may damage the connector NOTE Fuel fills of less than 9 5 liters 2 5 gallons require at least 10 minutes to update the fuel gauge indication Key in ON position Select the instrument cluster FUELLEVEL active command Trigger mon...

Page 3278: ...he fuel gauge operate correctly B3 CHECK THE FUEL TANK Check the fuel tank for any damage or deformation Is the fuel tank OK Yes GO to B4 No INSTALL a new fuel tank REFER to Section 310 01 TEST the system for normal operation B4 CHECK THE FUEL PUMP ASSEMBLY Check the fuel pump assembly in tank mounting float float rod wiring and connections for damage or obstruction Is the fuel pump assembly and w...

Page 3279: ... No REPAIR the circuit TEST the system for normal operation B7 CHECK FUEL PUMP MODULE GROUND CIRCUIT 327 BK OG AND CIRCUIT 397 BK WH Measure the resistance between the instrument cluster C220b pin 20 circuit 397 BK WH harness side and the fuel pump module C463 pin 8 circuit 327 BK OG harness side Is the resistance less than 5 ohms Yes GO to B8 No REPAIR the circuit s in question TEST the system fo...

Page 3280: ...to 0 50 and 100 Did the gauge display L at 0 the middle of the gauge at 50 and H at 100 Yes GO to C2 No GO to C3 C2 CHECK CIRCUIT 31 WH RD FOR OPEN OR SHORT TO GROUND Key in OFF position Disconnect Instrument Cluster C220b Disconnect Oil Pressure Switch C103 Measure the resistances between the instrument cluster C220b pin 16 circuit 31 WH RD harness side and the oil pressure switch C103 circuit 31...

Page 3281: ...tool Instrument Cluster Active Command Trigger instrument cluster active command ENGCOOLNT Monitor the engine coolant temperature gauge while adjusting the ENGCOOLNT active command to read 50 and 100 Does the temperature gauge start at cold move to half at 50 and full hot at 100 Yes REFER to the Powertrain Control Emissions Diagnosis PC ED manual No GO to D2 D2 CHECK FOR CORRECT INSTRUMENT CLUSTER...

Page 3282: ...istance between the generator C102a pin 1 circuit 904 LG RD harness side and the instrument cluster C220a pin 5 circuit 904 LG RD harness side and between the generator C102a pin 1 circuit 904 LG RD harness side and ground Is the resistance less than 5 ohms between the generator and the instrument cluster and greater than 10 000 ohms between the generator and ground Yes The system is operating cor...

Page 3283: ...eat correctly Operate the system and verify the concern is still present Is the concern still present Yes INSTALL a new instrument cluster REFER to Instrument Cluster in this section TEST the system for normal operation No The system is operating correctly at this time Concern may have been caused by a loose or corroded connector CLEAR the DTCs REPEAT the self test Test Step Result Action to Take ...

Page 3284: ...NING INDICATOR IS NEVER ALWAYS ON Check the fuel gauge for correct operation Is the fuel gauge operating correctly Yes GO to H3 No Go To Pinpoint Test B H3 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all instrument cluster connectors Check for corrosion pushed out pins Connect all instrument cluster connectors and make sure they seat correctly Operate the system and verify the concer...

Page 3285: ... position Is the odometer displaying all dashes Yes REFER to the Powertrain Control Emissions Diagnosis PC ED manual No GO to J2 J2 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all instrument cluster connectors Check for corrosion pushed out pins Connect all instrument cluster connectors and make sure they seat correctly Operate the system and verify the concern is still present Is th...

Page 3286: ...afety belt warning indicator illuminate for approximately three seconds and turn off Yes GO to K10 No GO to K4 K4 DETERMINE IF SAFETY BELT INDICATOR CIRCUIT IS SHORTED TO GROUND Buckle the driver safety belt Is the safety belt indicator always on Yes GO to K5 No GO to K7 K5 CHECK IF THE GEM IS INTERNALLY GROUNDED Key in OFF position Disconnect GEM C201e Key in ON position Observe the safety belt w...

Page 3287: ...nect Instrument Cluster C220a Measure the resistance between the GEM C201e pin 26 circuit 450 DG LG harness side and instrument cluster C220a pin 4 circuit 450 DG LG harness side Is the resistance less than 5 ohms Yes GO to K11 No REPAIR the circuit TEST the system for normal operation K10 CHECK FOR CORRECT GEM OPERATION Disconnect all GEM connectors Check for corrosion pushed out pins Connect all...

Page 3288: ...K SPEEDOMETER OPERATION Connect the diagnostic tool Key in ON position Enter the following diagnostic mode on the diagnostic tool Instument Cluster Active Command Trigger the instrument cluster active command SPDOMETER Scroll to 0 50 and 100 Did the speedometer display read 0 at 0 half the speedometer display at 50 and the full speedometer display at 100 Yes REFER to the Powertrain Control Emissio...

Page 3289: ...ter connectors Check for corrosion pushed out pins Connect all instrument cluster connectors and make sure they seat correctly Operate the system and verify the concern is still present Is the concern still present Yes INSTALL a new instrument cluster REFER to Instrument Cluster in this section TEST the system for normal operation No The system is operating correctly at this time Concern may have ...

Page 3290: ...ating correctly at this time Concern may have been caused by a loose or corroded connector CLEAR the DTCs REPEAT the self test Test Step Result Action to Take O1 CHECK IF THE GEM IS RECEIVING THE CORRECT IGNITION SWITCH STATUS CAUTION Use the correct probe adapter s when making measurements Failure to use the correct probe adapter s may damage the connector Connect the diagnostic tool Key in ON po...

Page 3291: ...1d pin 4 circuit 128 VT YE harness side and the parking brake switch C306 pin 1 circuit 22 LB BK harness side Is the resistance less than 5 ohms Yes GO to O7 No REPAIR the circuit TEST the system for normal operation O7 CHECK CIRCUIT 1205 BK FOR OPEN Measure the resistance between the parking brake switch C306 pin 2 circuit 1205 BK harness side and ground Is the resistance less than 5 ohms Yes INS...

Page 3292: ...UIT 128 VT YE FOR AN OPEN Key in OFF position Measure the resistance between the GEM C201e pin 13 circuit 128 VT YE harness side and the instrument cluster C220b pin 14 circuit 128 VT YE harness side Is the resistance less than 5 ohms Yes GO to O15 No REPAIR the circuit TEST the system for normal operation O11 CHECK THE BRAKE FLUID LEVEL SWITCH FOR AN INTERNAL GROUND Key in OFF position Disconnect...

Page 3293: ...hey seat correctly Operate the system and verify the concern is still present Is the concern still present Yes INSTALL a new GEM REFER to Section 419 10 TEST the system for normal operation No The system is operating correctly at this time Concern may have been caused by a loose or corroded connector CLEAR the DTCs REPEAT the self test O15 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect ...

Page 3294: ...ator on Yes GO to P5 No GO to P3 P3 CHECK THE INSTRUMENT CLUSTER INPUT Key in OFF position Disconnect Generator C102c Connect a fused 10A jumper wire between the generator C102c pin 1 circuit 904 LG RD harness side and ground Key in ON position Does the charging system indicator illuminate Yes INSTALL a new generator REFER to Section 414 02 TEST the system for normal operation No GO to P4 P4 CHECK...

Page 3295: ...s Check for corrosion pushed out pins Connect all instrument cluster connectors and make sure they seat correctly Operate the system and verify the concern is still present Is the concern still present Yes INSTALL a new instrument cluster REFER to Instrument Cluster in this section TEST the system for normal operation No The system is operating correctly at this time Concern may have been caused b...

Page 3296: ...ction TEST the system for normal operation No The system is operating correctly at this time Concern may have been caused by a loose or corroded connector CLEAR the DTCs REPEAT the self test Test Step Result Action to Take R1 CHECK THE ABS WARNING INDICATOR OPERATION CAUTION Use the correct probe adapter s when making measurements Failure to use the correct probe adapter s may damage the connector...

Page 3297: ...IR the circuit TEST the system for normal operation R4 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all instrument cluster connectors Check for corrosion pushed out pins Connect all instrument cluster connectors and make sure they seat correctly Operate the system and verify the concern is still present Is the concern still present Yes INSTALL a new instrument cluster REFER to Instrum...

Page 3298: ...cern may have been caused by a loose or corroded connector CLEAR the DTCs REPEAT the self test Test Step Result Action to Take T1 CHECK THE TURN SIGNAL AND HAZARD LAMPS OPERATION CAUTION Use the correct probe adapter s when making measurements Failure to use the correct probe adapter s may damage the connector Key in ON position Operate the left and right turn signals Operate the hazard lamps Do t...

Page 3299: ...ectly Operate the system and verify the concern is still present Is the concern still present Yes INSTALL a new instrument cluster REFER to Instrument Cluster in this section TEST the system for normal operation No The system is operating correctly at this time Concern may have been caused by a loose or corroded connector CLEAR the DTCs REPEAT the self test Test Step Result Action to Take U1 DETER...

Page 3300: ...uster REFER to Instrument Cluster in this section TEST the system for normal operation No The system is operating correctly at this time Concern may have been caused by a loose or corroded connector CLEAR the DTCs REPEAT the self test Test Step Result Action to Take V1 CHECK THE BATTERY POWER SUPPLY TO THE INSTRUMENT CLUSTER CAUTION Use the correct probe adapter s when making measurements Failure ...

Page 3301: ...Yes GO to V4 No REPAIR the circuit TEST the system for normal operation V4 CHECK GROUND CIRCUIT 397 BK WH FOR AN OPEN Key in OFF position Measure the resistance between the instrument cluster C220b pin 20 circuit 397 BK WH harness side and ground Is the resistance less than 5 ohms Yes GO to V5 No REPAIR the circuit TEST the system for normal operation V5 CHECK GROUND CIRCUIT 1205 BK FOR OPEN Measu...

Page 3302: ...ern may have been caused by a loose or corroded connector CLEAR the DTCs REPEAT the self test Test Step Result Action to Take CAUTION Use the correct probe adapter s when making measurements Failure to use the correct probe adapter s may damage the connector W1 CHECK THE GENERIC ELECTRONIC MODULE GEM POWER SUPPLY Key in OFF position Disconnect Generic Electronic Module GEM C201a Disconnect GEM C20...

Page 3303: ...than 5 ohms Yes GO to W3 No REPAIR the circuit s in question TEST the system for normal operation W3 CHECK CIRCUIT 397 BK WH FOR SHORT TO POWER Measure the voltage between the GEM C201b pin 4 circuit 397 BK WH harness side and ground Is any voltage present Yes REPAIR the circuit TEST the system for normal operation No REFER to Section 418 00 ...

Page 3304: ...nd cable For additional information refer to Section 414 01 2 Remove the headlamp switch knob Pull out the headlamp switch knob and insert a thin tool in the slot to release the knob from the shaft 3 Remove the screws and remove the instrument cluster finish panel 4 Remove the screws and pull the instrument cluster forward to expose the electrical connector SECTION 413 01 Instrument Cluster 2003 M...

Page 3305: ...the electrical connectors and boost pressure line and remove the instrument cluster Except Cobra 6 Disconnect the electrical connectors and remove the instrument cluster All vehicles 7 To install reverse the removal procedure ...

Page 3306: ......

Page 3307: ...1 Remove the instrument cluster Refer to Instrument Cluster in this section 2 Remove the necessary instrument cluster bulbs by rotating one quarter turn counterclockwise 3 To install reverse the removal procedure SECTION 413 01 Instrument Cluster 2003 Mustang Workshop Manual ...

Page 3308: ... and Installation 1 Remove the instrument cluster Refer to Instrument Cluster in this section 2 Remove the screws and remove the instrument cluster lens 3 To install reverse the removal procedure SECTION 413 01 Instrument Cluster 2003 Mustang Workshop Manual ...

Page 3309: ...IONS SECTION 413 06 Horn 2003 Mustang Workshop Manual Torque Specifications Description Nm lb ft lb in Horn retaining screw 10 89 Horn switch retaining bolts 5 40 Driver side air bag module retaining screws 12 9 ...

Page 3310: ...stem consists of the following dual horns one high pitched one low pitched horn switch located underneath the driver side air bag module 043B13 horn relay located in the central junction box CJB SECTION 413 06 Horn 2003 Mustang Workshop Manual ...

Page 3311: ...Manual Special Tool s 73 Digital Multimeter or equivalent 105 R0051 Visual Inspection Chart Mechanical Electrical Damaged horns Damaged horn switch Damaged air bag sliding contact 14A664 Blown battery junction box BJB Fuse Horn Relay 20A Damaged wiring harness Damaged connections Damaged horn relay Damaged horn switch Symptom Chart Condition Possible Sources Action The horn does not sound BJB Fuse...

Page 3312: ...han 10 volts Yes GO to A2 No REPAIR the circuit in question TEST the system for normal operation A2 CHECK HORN RELAY Check the horn relay refer to Wiring Diagrams Cell 149 Is the horn relay OK Yes GO to A3 No INSTALL a new horn relay TEST the system for normal operation A3 CHECK HORN SWITCH SIGNAL TO HORN RELAY Measure the resistance between horn relay connector Pin 1 Circuit 6 YE LG harness side ...

Page 3313: ...system for normal operation No REPAIR the circuit TEST the system for normal operation A5 CHECK WIRE BETWEEN HORN RELAY AND AIR BAG SLIDING CONTACT Key in OFF position Deactivate the air bag system refer to Section 501 20B Disconnect Air Bag Sliding Contact C218a Measure the resistance between air bag sliding contact C218a Pin 2 Circuit 6 YE LG harness side and horn relay connector Pin 1 Circuit 6...

Page 3314: ... normal operation No INSTALL a new steering wheel switch harness TEST the system for normal operation Test Step Result Action to Take B1 CHECK HORN CIRCUIT 1 DB Key in OFF position Disconnect Horn Relay Does the horn continue to sound Yes REPAIR Circuit 1 DB for short to battery TEST the system for normal operation No GO to B2 B2 CHECK HORN RELAY Check the horn relay refer to Wiring Diagrams Cell ...

Page 3315: ...ess from the air bag sliding contact Does the horn continue to sound Yes INSTALL a new air bag sliding contact REFER to Section 501 20B TEST the system for normal operation No GO to B6 B6 CHECK STEERING WHEEL SWITCH HARNESS Inspect the steering wheel switch harness for shorts opens or any damage Is the steering wheel switch harness OK Yes INSTALL a new horn switch REFER to Switch Horn TEST the sys...

Page 3316: ...to Section 501 20B 2 Remove the switches 1 Disconnect the horn wire from the switches 2 Remove the horn switch screws and remove the switches Installation 1 To install reverse the removal procedure Prove out the air bag system Refer to Section 501 20B SECTION 413 06 Horn 2003 Mustang Workshop Manual ...

Page 3317: ......

Page 3318: ...es The warning device system consists of the following components door ajar switches generic electronic module GEM key in ignition warning switch safety belt switch parklamp switch SECTION 413 09 Warning Devices 2003 Mustang Workshop Manual ...

Page 3319: ...itch circuits are in the RUN state and when the GEM detects a chime is requested from the airbag system circuit Refer to the Chime Duration Table for audible output duration time and priority ratings Door Ajar Warning Chime The door ajar warning chime activates when the GEM detects the ignition switch circuits are in the RUN state and when the GEM detects the driver or passenger door is ajar from ...

Page 3320: ...rrent safety belt warning is complete If the driver safety belt is not buckled approximately five seconds after the safety belt warning light has turned off the belt minder reminds the driver that their safety belt is unbuckled by intermittently sound a chime and illuminating the safety belt warning lamp in the instrument cluster While activated the belt minder alternates the chime and indicator f...

Page 3321: ...and record the continuous diagnostic trouble codes DTCs erase the continuous DTCs and carry out self test diagnostics for the GEM 7 If the DTCs retrieved are related to the concern go to the GEM Diagnostic Trouble Code DTC Index to continue diagnostics 8 If no DTCs related to the concern are retrieved proceed to the Symptom Chart to continue diagnostics 9 If the DTCs retrieved are for the RCM refe...

Page 3322: ...le RCM Circuitry Generic electronic module GEM Ignition switch Go To Pinpoint Test C The door ajar chime does not operate correctly Driver door ajar switch Passenger door ajar switch Circuitry Generic electronic module GEM Ignition switch Go To Pinpoint Test D The headlamp on reminder chime does not operate correctly Headlamp switch Circuitry Generic electronic module GEM Driver door ajar switch I...

Page 3323: ...d corroded terminals Complete the entire pinpoint test related to the symptom before installing a new GEM PINPOINT TEST A NO COMMUNICATION WITH THE GENERIC ELECTRONIC MODULE GEM Test Step Result Action to Take A1 CHECK THE GENERIC ELECTRONIC MODULE GEM POWER SUPPLY Key in OFF position Disconnect Generic Electronic Module GEM C201a Disconnect GEM C201b Key in ON position Using the following table m...

Page 3324: ...IGN_S and IGN_R while cycling the ignition switch through the OFF ACC RUN START and key out positions Do the PID values agree with the ignition switch states Yes GO to B2 No GO to B4 B2 CHECK GEM INTERNAL TONE OPERATION Enter the following diagnostic mode on the diagnostic tool GEM Active Command Trigger the GEM Active Command CHIME ON and OFF Does the chime operate correctly Yes GO to B3 No GO to...

Page 3325: ...d ground while cycling the ignition switch through all positions Is the voltage greater than 10 volts in the RUN and ACC positions only Yes GO to B6 No REPAIR the CJB REPEAT the self test CLEAR the DTCs B6 CHECK GEM VOLTAGE INPUT CIRCUITS FOR OPEN IGNITION SWITCH CIRCUIT 911 WH LG Disconnect CJB Fuse 28 15A Disconnect GEM C201e Insert the ignition key Measure the resistance between GEM C201e pin 8...

Page 3326: ...PEAT the self test CLEAR the DTCs B9 CHECK GEM VOLTAGE INPUT CIRCUITS FOR SHORT TO POWER IGNITION SWITCH CIRCUITS 911 WH LG AND 1002 BK PK Key in OFF position Disconnect CJB Fuse 28 15A Disconnect CJB Fuse 32 15A Disconnect GEM C201e Remove the ignition key Measure the voltage between GEM C201e pin 8 circuit 911 WH LG harness side and ground and between GEM C201e pin 22 circuit 1002 BK PK harness ...

Page 3327: ... the self test Test Step Result Action to Take C1 CHECK CONTINUOUS DTCS AND RESTRAINT CONTROL MODULE RCM Connect the diagnostic tool Enter the following diagnostic mode on the diagnostic tool RCM On Demand Self Test Carry out Continuous DTCs and On Demand RCM Self Tests Are any RCM DTCs received Yes REFER to Section 501 20B No GO to C2 C2 CHECK IGNITION STATES Enter the following diagnostic mode o...

Page 3328: ...r than 10 000 ohms Yes GO to C8 No REPAIR the circuit REPEAT the self test CLEAR the DTCs C6 CHECK CIRCUIT 1083 LB BK FOR SHORT TO POWER Disconnect RCM C2041e Disconnect GEM C201e Measure the voltage between GEM C201e pin 10 circuit 1083 LB BK harness side and ground Is voltage greater than 10 volts Yes REPAIR the circuit REPEAT the self test CLEAR the DTCs No GO to C7 C7 CHECK CIRCUIT 1083 LB BK ...

Page 3329: ...ATES Connect the diagnostic tool Enter the following diagnostic mode on the diagnostic tool GEM PID Monitor the GEM PIDS IGN_KEY IGN_A IGN_S and IGN_R while cycling the ignition switch through the OFF ACC RUN START and key out positions Do the PID values agree with the ignition switch states Yes GO to D2 No GO to Pinpoint Test B D2 CHECK GEM INTERNAL TONE OPERATION Enter the following diagnostic m...

Page 3330: ... diagnostic mode on the diagnostic tool GEM PID Monitor the GEM PID D_DR_SW Does GEM PID D_DR_SW read CLOSED Yes INSTALL a new driver door ajar switch REFER to Section 501 14A REPEAT the self test CLEAR the DTCs No GO to D7 D7 CHECK CIRCUIT 765 YE BK FOR SHORT TO GROUND BETWEEN GEM AND DRIVER DOOR AJAR SWITCH Disconnect GEM C201c Measure the resistance between GEM C201c pin 13 circuit 765 YE BK ha...

Page 3331: ...D Disconnect Driver Door Ajar Switch C526 Measure the resistance between driver door ajar switch C526 pin 1 circuit 1205 BK harness side and ground Is the resistance less than 5 ohms Yes INSTALL a new driver door ajar switch REFER to Section 501 14A REPEAT the self test CLEAR the DTCs No REPAIR the circuit REPEAT the self test CLEAR the DTCs D11 ISOLATE OPEN OR SHORT TO GROUND ON CIRCUIT 761 GN RD...

Page 3332: ... circuit REPEAT the self test CLEAR the DTCs D14 ISOLATE OPEN CIRCUIT 761 GN RD Disconnect Passenger Door Ajar Switch C602 Enter the following diagnostic mode on the diagnostic tool GEM PID Connect a 10A fused jumper wire between the passenger door ajar switch C602 pin 2 circuit 761 GN RD harness side and ground while monitoring the GEM PID P_DR_SW Does GEM PID P_DR_SW read AJAR with jumper wire i...

Page 3333: ...for corrosion for pushed out pins connector seated correctly Connect any disconnected connectors Make sure all other system connectors are fully seated Operate the system and verify the concern is still present Is the concern still present Yes INSTALL a new GEM REFER to Section 419 10 CLEAR the DTCs REPEAT the GEM self test No The system is operating correctly at this time Concern may have been ca...

Page 3334: ... indicate CLOSED and AJAR correctly Yes GO to E5 No GO to Pinpoint Test D E5 MONITOR EXTERIOR LAMP INPUT FOR CORRECT STATE Key in OFF position Enter the following diagnostic mode on the diagnostic tool GEM PID Monitor the GEM PID PARK_SW while triggering the headlamp switch ON and OFF Do the GEM PID PARK_SW values indicate ON and OFF correctly Yes GO to E9 No GO to E6 E6 CHECK EXTERIOR LAMP INPUT ...

Page 3335: ...out pins connector seated correctly Connect any disconnected connectors Make sure all other system connectors are fully seated Operate the system and verify the concern is still present Is the concern still present Yes INSTALL a new GEM REFER to Section 419 10 CLEAR the DTCs REPEAT the GEM self test No The system is operating correctly at this time Concern may have been caused by a loose or corrod...

Page 3336: ...cluster safety belt indicator lamp Does instrument cluster safety belt indicator lamp illuminate for approximately three seconds Yes GO to F11 No REFER to Section 413 01 F5 DETERMINE IF CIRCUIT 85 BN LB IS OPEN OR SHORTED TO GROUND Enter the following diagnostic mode on the diagnostic tool GEM PID Monitor the GEM PID D_SBELT while buckling and unbuckling the driver safety belt Does the GEM PID D_S...

Page 3337: ...N BETWEEN GEM AND SEATBELT SWITCH Disconnect Safety Belt Switch C323 Disconnect GEM C201b Measure the resistance between GEM C201b pin 8 circuit 85 BN LB harness side and safety belt switch C323 pin 2 circuit 85 BN LB harness side Is the resistance less than 5 ohms Yes GO to F11 No REPAIR the circuit CLEAR the DTCs TEST the system for normal operation F10 CHECK CIRCUIT 1205 BK FOR AN OPEN CIRCUIT ...

Page 3338: ...t any disconnected connectors Make sure all other system connectors are fully seated Operate the system and verify the concern is still present Is the concern still present Yes INSTALL a new GEM REFER to Section 419 10 CLEAR the DTCs REPEAT the GEM self test No The system is operating correctly at this time Concern may have been caused by a loose or corroded connector CLEAR the DTCs REPEAT the sel...

Page 3339: ...t unbuckled This portion of the procedure can be done before or during belt minder warning activation 4 Turn the parklamps headlamps on then off 5 Buckle then unbuckle the safety belt three times ending with the safety belt unbuckled After this step the safety belt warning lamp will be illuminated for three seconds 6 Within seven seconds of the safety belt warning lamp turning off buckle then unbu...

Page 3340: ......

Page 3341: ...REMOVAL AND INSTALLATION Switch Door Ajar Removal and Installation For additional information refer to Section 501 14A SECTION 413 09 Warning Devices 2003 Mustang Workshop Manual ...

Page 3342: ...eering column and press the release tab while pulling out the ignition switch lock cylinder 2 Remove the key in ignition warning switch 1 Release the clip 2 Push the key in ignition warning switch off the rear of the ignition switch lock cylinder Installation 1 To install reverse the removal procedure Verify ignition switch lock cylinder operation SECTION 413 09 Warning Devices 2003 Mustang Worksh...

Page 3343: ......

Page 3344: ...REMOVAL AND INSTALLATION Module Generic Electronic GEM Removal and Installation For additional information refer to Section 419 10 SECTION 413 09 Warning Devices 2003 Mustang Workshop Manual ...

Page 3345: ...cifications Item Specification Generator 4 6L Cobra 120 amps 6 000 pulley rpm 2 87 1 ratio internal regulator 4 6L Mach1 120 amps 6 000 pulley rpm 2 72 1 ratio internal regulator 4 6L 2V 110 amps 6 000 pulley rpm 3 16 1 ratio internal regulator 3 8L 110 amps 6 000 pulley rpm 2 79 1 ratio internal regulator ...

Page 3346: ...e A circuit This A circuit voltage battery sense circuit is compared to a set voltage internal to the regulator and the regulator controls the generator field current to maintain the correct generator output The set voltage will vary with temperature and is typically higher in cold temperatures than in warm temperatures This allows for better battery recharge in the winter and reduces the chance o...

Page 3347: ...ircuit is used to sense battery voltage This voltage is used by the regulator to determine generator output This circuit is also used to supply current to the generator field rotor The amount of current supplied to the rotor determines generator output ...

Page 3348: ...information Principles of Operation SECTION 414 00 Charging System General Information 2003 Mustang Workshop Manual Special Tool s 73III Automotive Meter 105 R0057 or equivalent SABRE Premium Battery and Electrical System Tester 010 00736 or equivalent Connector C102c End View A Circuit 36 YE WH I Circuit 904 LG RD ...

Page 3349: ...itive Output Circuit 38 B BK OG The generator output is supplied through the battery positive output B terminal on the back of the generator to the battery and electrical system I Circuit 904 LG RD The I ignition circuit is used to turn on the voltage regulator This circuit is powered up with the ignition key in the run position This circuit is also used to turn the charging system warning indicat...

Page 3350: ...N and the engine off the charging system warning indicator light should be on With the engine running the charging system warning indicator light should be off 4 Verify the battery is being charged Carry out the Battery Load Test Refer to Component Tests in this section 5 If the customer concern is verified after the initial inspection refer to the Symptom Chart to determine which tests to carry o...

Page 3351: ...ltage regulator Generator Go To Pinpoint Test B The system overcharges the battery voltage is greater than 15 5 volts Circuitry Voltage regulator Generator Go To Pinpoint Test C The charging system warning indicator is on with the engine running and the battery increases voltage Circuitry Instrument cluster Voltage regulator Generator Go To Pinpoint Test D The charging system warning indicator is ...

Page 3352: ...RAINS Carry out the Battery Drain Test Refer to Component Tests in this section Are there any excessive current drains Yes REPAIR as necessary TEST the system for normal operation No GO to A4 A4 CHECK FOR CURRENT DRAINS WHICH SHUT OFF WHEN THE BATTERY IS DISCONNECTED Carry out the Battery Electronic Drains Which Shut Off When the Battery Cable is Disconnected Test Refer to Component Tests in this ...

Page 3353: ... Key in ON position With the ignition switch in the RUN position and the engine off measure the voltage between the generator C102c 4 6L 4V or C102a 3 8L or 4 6L 2V pin 1 circuit 904 LG RD harness side and ground Is the voltage equal to battery positive voltage B Yes GO to B4 No REPAIR the circuit TEST the system for normal operation B4 CHECK FOR VOLTAGE DROP IN B CIRCUIT 38 YE WH Key in START pos...

Page 3354: ...voltage drop between the generator C102c 4 6L 4V or C102a 3 8L or 4 6L 2V pin 3 circuit 36 YE WH harness side and positive battery terminal Is the voltage drop less than 0 5 volt Yes GO to C2 No REPAIR the high resistance in A circuit 36 YE WH TEST the system for normal operation C2 CHECK GENERATOR AND BATTERY GROUND CONNECTIONS Key in OFF position Check the ground connections between the voltage ...

Page 3355: ...EFER to Section 414 02 TEST the system for normal operation Test Step Result Action to Take E1 CHECK THE CHARGING SYSTEM WARNING INDICATOR LAMP Disconnect Generator C102c 4 6L 4V or C102a 3 8L or 4 6L 2V With the engine off connect a fused 15A jumper wire between the generator C102c 4 6L 4V or C102a 3 8L or 4 6L 2V pin 1 circuit 904 LG RD harness side and ground Key in ON position Is the charging ...

Page 3356: ...n With the engine running note the charging system warning indicator operation Does the charging system warning indicator lamp flicker Yes REFER to Section 414 02 TEST the system for normal operation No REPAIR loose connection s in circuits TEST the system for normal operation Test Step Result Action to Take G1 CHECK FOR ACCESSORY DRIVE NOISE Check the accessory drive belt for damage and correct i...

Page 3357: ...on G4 CHECK GENERATOR FOR MECHANICAL NOISE Key in OFF position Connect Generator C102c 4 6L 4V or C102a 3 8L or 4 6L 2V Key in START position Turn all accessories off With the engine running use a stethoscope or equivalent listening device to probe the generator for unusual mechanical noise Is the generator the noise source Yes INSTALL a new generator REFER to Section 414 02 TEST the system for no...

Page 3358: ...gital ammeter must be used Use of a test lamp or voltmeter is not an accurate method due to the number of electronic modules 1 Make sure the junction box fuse panels are accessible without turning on interior and underhood lights 2 Drive the vehicle at least five minutes and over 48 km h 30 mph to turn on and exercise vehicle systems 3 Allow the vehicle to sit with the key off for at least 40 minu...

Page 3359: ...e drain is most likely caused by an inoperative electronic component As in previous tests remove the fuses from the battery central junction box one at a time to locate the problem circuit Generator On Vehicle Tests CAUTION To prevent damage to the generator do not make jumper wire connections except as directed CAUTION Do not allow any metal object to come in contact with the housing and the inte...

Page 3360: ...increases as specified the charging system is operating normally 6 With the engine running at 2 000 rpm adjust the tester load bank to determine the output of the generator Generator output should be at least 58 amps Generator On Vehicle Tests No Load Test 1 Switch the battery tester to the voltmeter function 2 Connect the voltmeter positive lead to the generator B output terminal circuit 38 BK OG...

Page 3361: ......

Page 3362: ...ft lb in Battery cable harness front support bracket nut 25 18 Battery cable terminal bolts 7 62 Battery hold down bolt 10 89 Battery junction box nut 20 15 Battery tray bolts 11 8 Front lower cable harness bracket nuts 11 8 Generator B cable nut 8 71 Battery cable bracket nut left upper 25 18 Battery ground cable nut engine block 25 18 Battery ground cable at the radiator support bolt 12 9 Positi...

Page 3363: ......

Page 3364: ...ation WARNING When lifting a battery excessive pressure on the end walls could cause acid to leak out through the vent caps resulting in personal injury damage to the vehicle or the battery WARNING Keep out of the reach of children Batteries contain sulfuric acid Avoid contact with skin eyes or clothing Also shield your eyes when working near the battery to protect against possible splashing of th...

Page 3365: ......

Page 3366: ...alyzer 162 00004 Visual Inspection Chart Mechanical Electrical Battery Battery mounting Battery cables Battery posts Test Step Result Action to Take A1 TEST BATTERY CONDITION NOTE No battery with a red test eye should be replaced The red eye only means the battery is discharged not necessarily defective NOTE Failure to fully charge the battery before retesting may cause false readings Verify the b...

Page 3367: ...No Does the meter read REPLACE BATTERY INSTALL a new battery Does the meter read BAD CELL REPLACE INSTALL a new battery ...

Page 3368: ...and power supplies if equipped Failure to follow these instructions may result in personal injury WARNING When lifting a battery excessive pressure on the end walls could cause acid to spew through the vent caps resulting in personal injury Lift with a battery carrier or with your hands on opposite corners Failure to follow these instructions may result in personal injury WARNING Keep out of the r...

Page 3369: ......

Page 3370: ... contain sulfuric acid Avoid contact with skin eyes or clothing Also shield your eyes when working near the battery to protect against possible splashing of the acid solution In case of acid contact with skin or eyes flush immediately with water for a minimum of 15 minutes and get prompt medical attention If acid is swallowed call a physician immediately Failure to follow these instructions may re...

Page 3371: ... battery Failure to follow these instructions may result in personal injury Remove the battery by lifting from the corners of the battery 5 NOTE When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle needs to be driven to relearn the strategy To install reverse the removal procedure ...

Page 3372: ......

Page 3373: ...ery to protect against possible splashing of the acid solution In case of acid contact with skin or eyes flush immediately with water for a minimum of 15 minutes and get prompt medical attention If acid is swallowed call a physician immediately Failure to follow these instructions may result in personal injury 1 Remove the battery For additional information refer to Battery in this section 2 Remov...

Page 3374: ......

Page 3375: ...inst possible splashing of the acid solution In case of acid contact with skin or eyes flush immediately with water for a minimum of 15 minutes and get prompt medical attention If acid is swallowed call a physician immediately Failure to follow these instructions may result in personal injury All vehicles 1 Remove the battery For additional information refer to Battery in this section 2 If equippe...

Page 3376: ...es 6 Remove the cable harness front support bracket by removing the nut and position the bracket aside Vehicles with 4 6L 4V engines 7 Remove the nut and position the left upper battery cable bracket aside All vehicles 8 Raise and support the vehicle For additional information refer to Section 100 02 9 NOTE 4 6L 4V shown 3 8L and 4 6L 2V similar If equipped remove the block heater plug from the bl...

Page 3377: ...ical connector 11 CAUTION Failure to tighten the negative cable ground nut may cause ground circuit failure or arcing NOTE 4 6L 2V shown 3 8L and 4 6L 4V similar Remove the battery ground cable nut at the engine block 12 Remove the nut and disconnect the generator electrical connections Position the cover aside ...

Page 3378: ...er cable harness bracket nuts 14 Pull the harness assembly downward until it clears the engine radiator area 15 NOTE 4 6L 2V shown 3 8L and 4 6L 4V similar Remove the right engine mount cable harness bracket nut 16 Remove the cover from the starter solenoid connections ...

Page 3379: ... motor mount then remove the entire battery cable harness from the vehicle Installation 1 NOTE When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle needs to be driven to relearn the strategy To install reverse the removal procedure ...

Page 3380: ......

Page 3381: ... 500 6 000 gen rpm 3 16 1 ratio Generator 4 6L 4V 58 120 amp max 1 500 6 000 gen rpm 2 87 1 ratio Electronic regulator internal to generator Torque Specifications Description Nm lb ft lb in Generator lower mounting bolts 4 6L 2V 25 18 Generator mounting bolt 3 8L upper 25 18 Generator mounting bolt 3 8L lower 47 35 Generator upper mounting bolts 4 6L 4V 50 37 Generator lower mounting bolt 4 6L 4V ...

Page 3382: ......

Page 3383: ...ts of the generator GEN internal voltage regulator The generator has an internal voltage regulator that is not installed separately The generator and voltage regulator are installed as an assembly SECTION 414 02 Generator and Regulator 2003 Mustang Workshop Manual ...

Page 3384: ...DIAGNOSIS AND TESTING Generator Refer to Section 414 00 SECTION 414 02 Generator and Regulator 2003 Mustang Workshop Manual ...

Page 3385: ...r additional information refer to Section 303 05 3 CAUTION This is a new style connector that has a press to release tab Pulling on the tab could result in damage to the connector or harness Disconnect the generator 10300 1 Disconnect the generator electrical connectors 2 Remove the battery positive cable nut 4 Remove the generator Remove the upper and lower generator bolts 5 To install reverse th...

Page 3386: ......

Page 3387: ... refer to Section 303 05 3 Remove the bolts on the upper generator bracket and remove the bracket 4 CAUTION This is a new style connector that has a press to release tab Pulling on the tab could result in damage to the connector or harness Disconnect the generator electrical connections 1 Remove the battery positive cable nut 1 and cable 2 Disconnect the generator electrical connector 5 Remove the...

Page 3388: ...6 To install reverse the removal procedure ...

Page 3389: ...d support the vehicle For additional information refer to Section 100 02 4 Disconnect the generator electrical connections Disconnect the electrical connector Position the cover aside and remove the nut and battery positive cable 5 Remove the upper and lower generator bolts 6 Remove the generator by lifting up and pulling it forward 7 To install reverse the removal procedure SECTION 414 02 Generat...

Page 3390: ......

Page 3391: ...5 00 Entertainment System General Information 2003 Mustang Workshop Manual Special Tool s 73III Automotive Meter 105 R0057 or equivalent Visual Inspection Chart Mechanical Electrical Audio unit Antenna or antenna cable Speakers mounting speaker cones Radio ignition interference capacitor radio frequency interference suppression bond or radio receiver hood bonding strap cleanliness Battery junction...

Page 3392: ...ized Ford audio system repair facility TEST the system for normal operation Poor reception Antenna connections Antenna cable Noise suppression equipment Audio unit Generator Ignition system Go To Pinpoint Test B Poor reception FM only FM signal out of range INFORM customer of methods for obtaining best reception Continuous SEEK SCAN in AM FM Antenna Antenna connections Audio unit Go To Pinpoint Te...

Page 3393: ...When the headlamp switch is in park or headlamp position and the ignition switch is in the RUN or ACC position the audio unit back lighting is inoperative all other I P lighting functions are normal Circuitry Audio unit REFER to Section 413 00 The audio unit has two items that can be dimmed the audio unit display and the control buttons one dims and the other does not Audio unit REMOVE the audio u...

Page 3394: ... an authorized Ford audio system facility TEST the system for normal operation A4 CHECK VOLTAGE AT THE AUDIO UNIT Key in OFF position Disconnect Audio Unit C290b Key in ON position Measure the voltage between the audio unit C290b pin 10 circuit 1002 BK PK harness side and ground and between the audio unit C290b pin 9 circuit 828 VT LB harness side and ground Are the voltages greater than 10 volts ...

Page 3395: ...Refer to Section 415 01 Check the radio receiver hood bonding strap and the body to chassis straps for integrity cleanliness and metal to metal contact NOTE The capacitor mounting points are used to complete the electrical circuit and must be mounted securely to clean surfaces Check the mounting and connecting circuits of the radio ignition interference capacitor for integrity cleanliness and meta...

Page 3396: ...the noise eliminated Yes INSTALL a new antenna cable TEST the system for normal operation No GO to B8 B8 SUBSTITUTE AUDIO UNIT Key in OFF position Substitute a known good audio unit Key in START position Verify the operation of the audio unit Is the noise eliminated Yes REMOVE the audio unit and SEND it to an authorized Ford audio system repair facility TEST the system for normal operation No GO t...

Page 3397: ...e between the antenna cable lead terminal and the end of the antenna grid wire 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 Substitute a known good antenna cable between the audio unit and the antenna Key in START position Check the operation of the audio unit Is the noise eliminated Yes INSTALL a new antenna ex...

Page 3398: ... 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 Disconnect Audio Unit C290b Disconnect Subwoofer Amplifier C4108a Disconnect Subwoofer Amplifier C4109b Measure the resistance between the subwoofer amplifier and the audio unit C290b and between the subwoofer amplifier and grou...

Page 3399: ...cuit 172 LB RD harness side and the audio unit C290a pin 5 circuit 172 LB RD harness side and between the subwoofer amplifier C4109b pin 6 circuit 172 LB RD harness side and ground 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 Yes GO to D6 No REPAIR the circuit s in question TEST the s...

Page 3400: ...FER AMPLIFIER NOTE Ground circuit 694 is located in the same cavity in all four subwoofer amplifiers Measure the resistance between affected subwoofer amplifier pin 2 circuit 694 BK LG and ground Is the resistance less than 5 ohms Yes GO to D10 No REPAIR the circuit s in question TEST the system for normal operation D10 CHECK FOR AN AUDIO SIGNAL TO THE AFFECTED SUBWOOFER AMPLIFIER Key in ON positi...

Page 3401: ...al operation No REPAIR the circuit s in question TEST the system for normal operation D12 CHECK FOR AN AUDIO SIGNAL AT THE AFFECTED SUBWOOFER Key in OFF position Connect Affected Subwoofer Amplifier Disconnect Affected Subwoofer Speaker Key in ON position Turn on the audio unit and check for a fluctuating AC voltage between affected subwoofer as follows For right subwoofer pin 4 circuit 187 DB OG ...

Page 3402: ...t 1 4 176 PK LG 3 3 179 OR RD 2 4 189 TN LB 4 3 187 DB OR Speaker Circuits Left Side Affected Subwoofer Speaker Pin Respective Amplifier Pin Circuit 1 4 176 PK LG 3 3 179 OR RD 2 4 189 TN LB 4 3 187 DB OR INSTALL a new subwoofer amplifier No REPAIR the circuit s in question TEST the system for normal operation Test Step Result Action to Take E1 CHECK FOR AUDIO UNIT OPERATION Key in ON position Tur...

Page 3403: ...SPEAKER S AND SUBWOOFER AMPLIFIERS Disconnect Subwoofer Amplifier C4108a Disconnect Subwoofer Amplifier C4109b Disconnect Affected Speaker s Measure the resistance between the subwoofer amplifier and the affected speaker s and between subwoofer amplifier and ground as follows Are the resistances less than 5 ohms between the subwoofer amplifier and the affected speaker s and greater than 10 000 Spe...

Page 3404: ...bwoofer 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 RR 1 7 822 BK LG RR 2 8 287 BK WH LR 1 7 822 BK LG LR 2 8 287 BK WH Yes GO to F5 No REPAIR the circuit s in question TEST the system for normal operation F5 CHECK CIRCUITS BETWEEN THE AUDIO UNIT AND THE SUBWOOFER ...

Page 3405: ...s and greater that 10 000 ohms between the subwoofer amplifier harness and ground Speaker Circuits Audio Unit C290a Pin Affected Subwoofer Amplifier Pin Circuit 2 8 172 LB RD 8 7 169 LG BK Yes SEND the audio unit to an authorized Ford audio system repair facility TEST the system for normal operation No REPAIR the circuit s in question TEST the system for normal operation F8 CHECK FOR AN AUDIO SIGN...

Page 3406: ...bwoofer speaker and greater that 10 000 ohms between the subwoofer speaker harness and ground Speaker Circuits Right Side Affected Subwoofer Speaker Pin Respective Amplifier Pin Circuit 1 4 176 PK LG 3 3 179 OR RD 2 4 189 TN LB 4 3 187 DB OR Speaker Circuits Left Side Affected Subwoofer Speaker Pin Respective Amplifier Pin Circuit 1 4 176 PK LG 3 3 179 OR RD 2 4 189 TN LB 4 3 187 DB OR Yes INSTALL...

Page 3407: ...orized Ford audio system repair facility TEST the system for normal operation Test Step Result Action to Take G1 CHECK POOR SOUND QUALITY IN ALL SPEAKERS Key in ON position Turn on the audio unit Carry out the speaker walk around test by pressing preset buttons 3 and 6 simultaneously Is there poor quality or distortion in all speakers Yes REMOVE the audio unit and SEND it to an authorized Ford aud...

Page 3408: ...ofer amplifiers C4108a LH or C4109a RH pin 1 circuit 694 BK LG harness side and ground and between the subwoofer amplifiers C4108a LH or C4109a RH pin 2 circuit 694 BK LG harness side and ground and between the subwoofer amplifiers C4108a LH or C4109a RH pin 3 circuit 694 BK LG harness side and ground Are the resistances less than 5 ohms Yes GO to H4 No REPAIR the circuit s in question TEST the sy...

Page 3409: ... Disconnect Subwoofer Amplifier C4109b Key in ON position Turn on the audio unit Measure the voltage between the subwoofer amplifier C4109b pin 5 circuit 828 VT LB harness side and ground between the subwoofer amplifier C4109b pin 6 circuit 828 VT LB harness side and ground and between the subwoofer amplifier C4109b pin 7 circuit 828 VT LB harness side and ground Are the voltages greater than 10 v...

Page 3410: ...circuit 169 LG BK harness side and the audio unit C290a pin 6 circuit 169 LG BK harness side and between the subwoofer amplifier C4109b pin 5 circuit 169 LG BK harness side and ground and between the subwoofer amplifier C4109b pin 6 circuit 172 LB RD harness side and the audio unit C290a pin 5 circuit 172 LB RD harness side and between the subwoofer amplifier C4109b pin 6 circuit 172 LB RD harness...

Page 3411: ...ion NOTE Audio signal circuits 169 and 172 are located in the same cavity on all four subwoofers Turn on the audio unit and check for a fluctuating AC voltage between affected subwoofer amplifier pin 8 circuit 172 LB RD and pin 7 circuit 169 LG BK Does the voltage vary as the volume is adjusted Yes GO to H14 No GO to H13 H13 CHECK AUDIO SIGNAL CIRCUITS AT THE AFFECTED SUBWOOFER AMPLIFIER FOR OPEN ...

Page 3412: ...LG BK harness side and between pin 3 circuit 179 OR RD and pin 1 circuit 176 PK LG harness side For left subwoofer pin 1 circuit 187 DB OR and pin 3 circuit 189 LG BK harness side and between pin 2 circuit 179 OR RD and pin 4 circuit 176 PK LG harness side Does the voltage vary as the volume is adjusted Yes INSTALL a new subwoofer speaker No GO to H15 H15 CHECK FOR AN OPEN AND SHORT TO GROUND BETW...

Page 3413: ... the operation of the audio unit Does the audio unit operate correctly Yes SEND the audio unit to an authorized Ford audio system repair facility TEST the system for normal operation No REMOVE the subwoofer amplifier and SEND it to an authorized Ford audio system repair facility TEST the system for normal operation Test Step Result Action to Take I1 CHECK SUBWOOFERS FOR LOUD POPS Key in ON positio...

Page 3414: ...ps are from the convertible LH subwoofer amplifier only REPAIR circuit 173 DG VT TEST the system for normal operation If the loud pops are from the convertible RH subwoofer amplifier only REPAIR circuit 174 GY BK TEST the system for normal operation ...

Page 3415: ...SPECIFICATIONS SECTION 415 01 Audio Unit 2003 Mustang Workshop Manual Torque Specifications Description Nm lb ft lb in Battery ground cable bolt 10 89 Amplifier bracket to body nut 25 18 ...

Page 3416: ...disc changer audio unit comes with the Mach 460 or Mach 1000 systems and speed sensitive volume control The Mach 460 system consists of eight speakers and two subwoofer amplifiers The Mach 1000 option adds two additional subwoofers and four additional amplifiers located in the luggage compartment Refer to the owner literature for complete audio system operating controls and functions SECTION 415 0...

Page 3417: ...DIAGNOSIS AND TESTING Audio System Refer to Section 415 00 SECTION 415 01 Audio Unit 2003 Mustang Workshop Manual ...

Page 3418: ...nt panel center finish panel For additional information refer to Section 501 12 2 Remove the audio unit 1 Remove the screws 2 Disconnect electrical connectors 3 Disconnect antenna cable 3 To install reverse the removal procedure SECTION 415 01 Audio Unit 2003 Mustang Workshop Manual ...

Page 3419: ...side the luggage compartment remove the forward panel 1 Remove the pin type retainers 2 Remove the forward panel 2 NOTE LH and RH subwoofer amplifiers are similar Remove the subwoofer amplifiers 1 Disconnect the electrical connectors 2 Remove the nuts 3 Remove the subwoofer amplifiers 3 To install reverse the removal procedure SECTION 415 01 Audio Unit 2003 Mustang Workshop Manual ...

Page 3420: ......

Page 3421: ...oofer Amplifier Coupe Removal and Installation 1 Remove the subwoofer amplifier 1 Remove the screws 2 Remove the subwoofer amplifier 2 To install reverse the removal procedure SECTION 415 01 Audio Unit 2003 Mustang Workshop Manual ...

Page 3422: ...sembly 1 Remove the two attaching nuts 2 Remove the screw 3 Disconnect the electrical connectors 2 Remove the subwoofer amplifiers Remove the bracket to body attaching nuts Disconnect the electrical connectors 3 To install reverse the removal procedure SECTION 415 01 Audio Unit 2003 Mustang Workshop Manual ...

Page 3423: ......

Page 3424: ...SPECIFICATIONS SECTION 415 02 Antenna 2003 Mustang Workshop Manual Torque Specifications Description Nm lb in Battery ground cable 10 89 ...

Page 3425: ...ase and cable antenna lead in cable The radio antenna uses a two piece coaxial cable to connect the audio unit to the antenna The front antenna lead in cable is connected to the audio unit and has an in line connector at the RH cowl side SECTION 415 02 Antenna 2003 Mustang Workshop Manual ...

Page 3426: ...DIAGNOSIS AND TESTING Antenna Refer to Section 415 00 SECTION 415 02 Antenna 2003 Mustang Workshop Manual ...

Page 3427: ...el 2 Disconnect the antenna in line connector 3 Remove the antenna base and cable 1 Remove the radio antenna base cap 2 Remove the screws 3 Remove the antenna base and cable Disconnect the antenna cable grommet Installation 1 To install reverse the removal procedure SECTION 415 02 Antenna 2003 Mustang Workshop Manual ...

Page 3428: ......

Page 3429: ...ve compartment by releasing the stops from the instrument panel 3 Disconnect the antenna in line connector 4 Remove the antenna lead in cable 1 Disconnect the pin type retainers 2 Remove the antenna lead in cable Installation 1 To install reverse the removal procedure SECTION 415 02 Antenna 2003 Mustang Workshop Manual ...

Page 3430: ......

Page 3431: ...SPECIFICATIONS SECTION 415 03 Speakers 2003 Mustang Workshop Manual Torque Specifications Description Nm lb ft lb in Subwoofer nut coupe 10 89 Subwoofer nut Mach 1000 25 18 ...

Page 3432: ...speakers On the coupe two are located in each door and four are in the subwoofer assembly On the convertible two speakers are in each door and two are mounted in each subwoofer assembly behind the rear quarter trim panels Both the coupe and convertible subwoofer assemblies are not repairable The MACH 1000 has all the components of the MACH 460 system plus two additional subwoofers located on each ...

Page 3433: ...DIAGNOSIS AND TESTING Speakers Refer to Section 415 00 SECTION 415 03 Speakers 2003 Mustang Workshop Manual ...

Page 3434: ...For additional information refer to Section 501 05 2 Remove the upper speaker access cover 3 Remove the upper speaker housing 1 Remove the screw 2 Remove the upper speaker housing 3 Disconnect the electrical connector 4 To install reverse the removal procedure SECTION 415 03 Speakers 2003 Mustang Workshop Manual ...

Page 3435: ......

Page 3436: ... front door trim panel 239420 For additional information refer to Section 501 05 2 Remove the speaker 18808 1 Remove the screws 2 Disconnect the electrical connector 3 Remove the speaker 3 To install reverse the removal procedure SECTION 415 03 Speakers 2003 Mustang Workshop Manual ...

Page 3437: ...nstallation 1 Remove the package tray trim panel Refer to Section 501 05 2 Remove the speaker 1 Remove the screws 2 Remove the speaker Disconnect the electrical connector 3 To install reverse the removal procedure SECTION 415 03 Speakers 2003 Mustang Workshop Manual ...

Page 3438: ...amplifier electrical connectors 3 NOTE Do not let the subwoofer assembly fall into the luggage compartment support the subwoofer assembly before removing the fasteners Remove the six nuts From inside the luggage compartment remove the subwoofer assembly Transfer the amplifiers to the new subwoofer assembly 4 To install reverse the removal procedure SECTION 415 03 Speakers 2003 Mustang Workshop Man...

Page 3439: ......

Page 3440: ... rear quarter trim panel For additional information refer to Section 501 05 2 Remove the subwoofer assembly 1 Disconnect the electrical connectors 2 Remove the screws 3 Remove the subwoofer assembly 3 To install reverse the removal procedure SECTION 415 03 Speakers 2003 Mustang Workshop Manual ...

Page 3441: ......

Page 3442: ... the rear quarter trim panel For additional information refer to Section 501 05 2 Remove the speaker 18808 1 Remove the screws 2 Disconnect the electrical connector 3 Remove the speaker 3 To install reverse the removal procedure SECTION 415 03 Speakers 2003 Mustang Workshop Manual ...

Page 3443: ...SPECIFICATIONS SECTION 417 01 Exterior Lighting 2003 Mustang Workshop Manual Torque Specifications Description Nm lb in Battery ground cable bolt 10 89 Rear lamp nuts 6 53 ...

Page 3444: ... stoplamp license lamps front turn lamps reversing lamps fog lamps if equipped headlamp switch 11654 fog lamp switch if equipped brake pedal position BPP switch 13480 multifunction switch 13K359 digital transmission range DTR sensor A T reversing lamp switch M T electronic flasher fog lamp relays if equipped SECTION 417 01 Exterior Lighting 2003 Mustang Workshop Manual ...

Page 3445: ...03 Mustang Workshop Manual Special Tool s 73III Automotive Meter or equivalent 105 R0057 Visual Inspection Chart Mechanical Electrical Damaged headlamp switch 11654 Damaged multifunction switch 13K359 Battery junction box BJB fuse 2 30A Central junction box CJB fuse s 38 20A 4 7 5A RH 10 7 5A LH Damaged wiring harness Loose or corroded connections Headlamp bulb Symptom Chart Condition Possible Sou...

Page 3446: ...Multifunction switch Go To Pinpoint Test F The flash to pass feature is inoperative Circuitry Multifunction switch CHECK Circuit 196 DB OG for an open REPAIR if necessary IF OK INSTALL a new multifunction switch REFER to Section 211 05 TEST the system for normal operation Test Step Result Action to Take A1 CHECK THE VOLTAGE TO THE HEADLAMP SWITCH Disconnect Headlamp Switch C205 Measure the voltage...

Page 3447: ...uit 15 RD YE harness side and ground Is the voltage greater than 10 volts Yes INSTALL a new multifunction switch REFER to Section 211 05 TEST the system for normal operation No INSTALL a new headlamp switch REFER to Lamp Switch Headlamp in this section TEST the system for normal operation Test Step Result Action to Take B1 CHECK THE VOLTAGE TO CJB FUSE 4 7 5A AND CJB FUSE 10 7 5A Key in OFF positi...

Page 3448: ...No REPAIR the circuit TEST the system for normal operation Test Step Result Action to Take C1 CHECK THE CIRCUIT 12 LG BK Disconnect LH Headlamp C1021 Measure the resistance between LH headlamp C1021 Pin 2 Circuit 12 LG BK harness side and CJB Fuse 38 20A Is the resistance less than 5 ohms Yes RECONNECT the LH headlamp 13008 GO to C2 No REPAIR the circuit TEST the system for normal operation C2 CHE...

Page 3449: ...ion No REPAIR the circuit TEST the system for normal operation Test Step Result Action to Take D1 CHECK THE VOLTAGE TO THE INOPERATIVE HEADLAMP BULB Disconnect Inoperative Headlamp Place the headlamp switch in the ON position Place the multifunction switch in the low beam position Measure the voltage between RH headlamp C1041 Pin 3 Circuit 1056 DB LG or LH headlamp C1021 Pin 3 Circuit 1055 WH LG h...

Page 3450: ...ion TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation Test Step Result Action to Take F1 CHECK THE HEADLAMP SWITCH Key in OFF position Disconnect Headlamp Switch C205 Are the headlamps on Yes GO to F2 No INSTALL a new headlamp switch REFER to Lamp Switch Headlamp in this section TEST the system for normal operation F2 CHECK THE MULTIFUNCTION SWITCH Dis...

Page 3451: ...Is the voltage greater than 0 volts Yes REPAIR the circuit TEST the system for normal operation No GO to F5 F5 CHECK CIRCUIT 1056 DB LG FOR VOLTAGE Disconnect Headlamp C1041 Measure the voltage between RH headlamp C1041 Pin 3 Circuit 1056 DB LG harness side and ground Is the voltage greater than 0 volts Yes REPAIR Circuit 1056 DB LG TEST the system for normal operations No REPAIR Circuit 1055 WH L...

Page 3452: ......

Page 3453: ...efer to the Symptom Chart Symptom Chart SECTION 417 01 Exterior Lighting 2003 Mustang Workshop Manual Special Tool s 73III Automotive Meter or equivalent 105 R0057 Visual Inspection Chart Mechanical Electrical Brake pedal position BPP switch Central junction box CJB fuse 41 15A Circuitry Bulb s Symptom Chart Condition Possible Sources Action The stoplamps are inoperative Central junction box CJB f...

Page 3454: ...ness side and C278 circuit 810 RD LG harness side Do the stoplamps illuminate Yes INSTALL a new BPP switch REFER to Lamp Switch Brake Pedal Position BPP in this section TEST the system for normal operation No REPAIR circuit 810 RD LG or 569 DG as necessary TEST the system for normal operation Test Step Result Action to Take H1 CHECK THE VOLTAGE TO THE INOPERATIVE STOPLAMP Disconnect Inoperative St...

Page 3455: ... resistance between the inoperative stoplamp connector and multifunction switch C202b pin 9 circuit 9 LG OG LH or C202b pin 5 circuit 5 OG LB RH Is the resistance less than 5 ohms Yes INSTALL a new multifunction switch REFER to Section 211 05 TEST the system for normal operation No REPAIR the circuit in question TEST the system for normal operation Test Step Result Action to Take I1 CHECK THE BRAK...

Page 3456: ... stoplamps continue to illuminate Yes GO to I5 No REPAIR the circuit TEST the system for normal operation I5 CHECK THE MULTIFUNCTION SWITCH Disconnect Multifunction Switch C202b Do the stoplamps continue to illuminate Yes If the high mounted stoplamp is illuminated REPAIR circuit 569 DG or 511 LG as necessary TEST the system for normal operation If only the LH stoplamp is illuminated REPAIR circui...

Page 3457: ......

Page 3458: ... to the next step 4 If the cause is not visually evident verify the symptom and refer to the Symptom Chart Symptom Chart SECTION 417 01 Exterior Lighting 2003 Mustang Workshop Manual Special Tool s 73 III Automotive Meter 105 R0057 or equivalent Visual Inspection Chart Mechanical Electrical Multifunction switch Central junction box CJB Fuse 13 15A CJB Fuse 18 15A Circuitry Electronic flasher Turn ...

Page 3459: ...h INSTALL a new multifunction switch REFER to Section 211 05 TEST the system for normal operation The hazard flasher lamps are always on Multifunction switch INSTALL a new multifunction switch REFER to Section 211 05 TEST the system for normal operation Test Step Result Action to Take J1 CHECK THE VOLTAGE TO THE ELECTRONIC FLASHER Disconnect Electronic Flasher C2141 Key in ON position Measure the ...

Page 3460: ...ation J3 CHECK THE CONTINUITY OF THE MULTIFUNCTION SWITCH Carry out the multifunction switch component test Refer to Wiring Diagrams Cell 149 for schematic and connector information Is the switch OK Yes INSTALL a new electronic flasher TEST the system for normal operation No INSTALL a new multifunction switch REFER to Section 211 05 TEST the system for normal operation Test Step Result Action to T...

Page 3461: ...e electronic flasher and greater than 10 000 ohms between the multifunction switch and ground GO to K3 No REPAIR the circuit TEST the system for normal operation K3 CHECK THE CONTINUITY OF THE MULTIFUNCTION SWITCH Carry out the multifunction switch component test Refer to Wiring Diagrams Cell 149 for schematic and connector information Is the switch OK Yes INSTALL a new electronic flasher TEST the...

Page 3462: ...al Tool s 73 III Automotive Meter or equivalent 105 R0057 Visual Inspection Chart Mechanical Electrical Damaged multifunction switch 13K359 Damaged headlamp switch 11654 Blown battery junction box BJB Fuse 2 30A Damaged wiring harness Loose or corroded connections Damaged parking rear or license lamp Symptom Chart Condition Possible Sources Action The parking rear or license lamps are inoperative ...

Page 3463: ...nce between headlamp switch C205 Pin R Circuit 14 BN harness side and ground Is the resistance less than 5 ohms Yes INSTALL a new headlamp switch REFER to Lamp Switch Headlamp TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation Test Step Result Action to Take M1 CHECK THE VOLTAGE TO THE INOPERATIVE LAMP S Key in OFF position Disconnect Inoperative Lamp P...

Page 3464: ...E HEADLAMP SWITCH Key in OFF position Disconnect Headlamp Switch C205 Key in ON position Are the parking rear or licences lamps on Yes REPAIR Circuit 14 BN for a short to battery TEST the system for normal operation No INSTALL a new headlamp switch REFER to Lamp Switch Headlamp TEST the system for normal operation ...

Page 3465: ...and Verification 1 Verify the customer concern by operating the fog lamps 2 Visually inspect for the following obvious signs of mechanical and electrical damage 3 If the concern is not visually evident determine the symptom and proceed to Symptom Chart Symptom Chart SECTION 417 01 Exterior Lighting 2003 Mustang Workshop Manual Special Tool s 73 III Automotive Meter or equivalent 105 R0057 Visual I...

Page 3466: ...1 CHECK THE PARK LAMPS Place the headlamp switch in the PARK position Place the multifunction switch in low beam position Do the park lamps illuminate Yes Turn off the headlamp switch GO to O2 No GO to Pinpoint Test L O2 CHECK THE FOG LAMP RELAYS Disconnect Fog Lamp Relay Disconnect Fog Lamp Interrupt Relay Check the fog lamp relay and fog lamp interrupt relay refer to Wiring Diagrams Cell 149 Are...

Page 3467: ...re the voltage between fog lamp relay connector Pin 30 Circuit 477 LB BK harness side and ground Is the voltage greater than 10 volts Yes GO to O6 No REPAIR the circuit TEST the system for normal operation O6 CHECK CIRCUIT 188 WH BK Disconnect Fog Lamp Switch C240 Measure the resistance between fog lamp switch C240 Pin 1 Circuit 188 WH BK harness side and fog lamp relay connector Pin 86 Circuit 18...

Page 3468: ...Circuit 188 WH BK connector side and fog lamp switch C240 Pin 2 Circuit 14 BN connector side with the fog lamp switch on Is the resistance less then 5 ohms Yes REPAIR Circuit 478 TN OG TEST the system for normal operation No INSTALL a new fog lamp switch TEST the system for normal operation Test Step Result Action to Take P1 CHECK THE GROUND TO THE FOG LAMP Key in OFF position Disconnect Inoperati...

Page 3469: ...78 TN OG TEST the system for normal operation Q2 CHECK FOG LAMP RELAY Check the fog lamp relay refer to Wiring Diagrams Cell 149 Is the fog lamp relay OK Yes RECONNECT the fog lamp relay GO to Q3 No INSTALL a new fog lamp relay TEST the system for normal operation Q3 CHECK FOG LAMP SWITCH Disconnect Fog Lamp Switch C240 Are the fog lamps off Yes INSTALL a new fog lamp switch TEST the system for no...

Page 3470: ......

Page 3471: ...03 Mustang Workshop Manual Special Tool s 73III Automotive Meter or equivalent 105 R0057 Visual Inspection Chart Mechanical Electrical Damaged digital transmission range DTR sensor automatic transmission A T Damaged reversing lamp switch manual transmission M T Blown central junction box CJB Fuse 11 15A Damaged wiring harness Loose or corroded connections Damaged reversing lamp Damaged DTR sensor ...

Page 3472: ...M T Key in ON position If equipped with A T measure the voltage between DTR sensor C167 Pin 9 Circuit 1087 OG harness side and ground If equipped with M T measure the voltage between reversing lamp switch C169 Circuit 1087 OG harness side and ground Is the voltage greater than 10 volts Yes GO to R2 No REPAIR the circuit TEST the system for normal operation R2 CHECK CIRCUIT 140 BK PK FOR OPEN Key i...

Page 3473: ...Circuit 1205 BK or RH reversing lamp C461 Circuit 1205 BK harness side and ground Is the resistance less than 5 ohms Yes REPAIR Circuit 140 BK PK for open TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation Test Step Result Action to Take S1 CHECK REVERSING LAMPS GROUND Key in OFF position Disconnect Inoperative Reversing Lamp Measure the resistance betw...

Page 3474: ... LAMP SWITCH M T Key in OFF position Disconnect DTR Sensor C167 A T Disconnect Reversing Lamp Switch C169 M T Set the parking brake Key in ON position Select REVERSE Are the reversing lamps illuminated Yes REPAIR Circuit 140 BK PK for short to battery TEST the system for normal operation No INSTALL a new DTR sensor A T or reversing lamp switch M T REFER to Section 307 01 Section 308 03A or Section...

Page 3475: ...g can be used to aim SAE VOR and VOL type headlamps Mechanical aimers can be used only with SAE type headlamps Lamps that can be aimed mechanically will have three nibs molded into the lens of the lamp Photometric Aiming 1 For the photometric aiming procedure refer to the appropriate photometric headlamp aimer instruction manual Screen Method Aiming All headlamp types NOTE Horizontal aim is not ne...

Page 3476: ...or screen at the same distance from the ground as previously recorded 4 NOTE This procedure should be done in a dark environment to effectively see the headlamp beam pattern Turn on the low beam headlamps to illuminate the wall or screen and open the hood 5 NOTE For SAE type headlamps the appearance of the beam pattern may vary between vehicles On the wall or screen locate the high intensity area ...

Page 3477: ... pattern The edge of this cutoff should be positioned 50 2 mm 2 in below the horizontal reference line 1 Horizontal reference line 2 Top edge of the beam pattern 3 High intensity zone Mechanical Aiming 1 For the mechanical aiming procedure refer to the appropriate mechanical headlamp aimer instruction manual ...

Page 3478: ......

Page 3479: ...r the headlamp where they can settle on the lens and reflector Never turn on the headlamps with the bulb removed 1 Remove the headlamp assembly For additional information refer to Lamp Assembly Headlamp 2 Rotate the headlamp bulb retainer counterclockwise 3 Remove the headlamp bulb and retainer Grasp the headlamp bulb by its base and remove the bulb Installation 1 WARNING The halogen bulb contains...

Page 3480: ......

Page 3481: ...se the headlamp retainers 2 Remove the headlamp assembly Disconnect the electrical connectors and replace the lamp if necessary Installation 1 To install reverse the removal procedure If necessary adjust the headlamps For additional information refer to Headlamp Adjustment in this section SECTION 417 01 Exterior Lighting 2003 Mustang Workshop Manual ...

Page 3482: ......

Page 3483: ...amp assembly 1 Disconnect the electrical connector 2 Remove the two screws 3 Remove the fog lamp assembly and replace the bulb if necessary Installation 1 NOTE Be sure the fascia clip is correctly installed on the bottom side of the fog lamp assembly bracket To install reverse the removal procedure SECTION 417 01 Exterior Lighting 2003 Mustang Workshop Manual ...

Page 3484: ......

Page 3485: ...1 Raise and support the vehicle For additional information refer to Section 100 02 2 Remove the fog lamp assembly 1 Disconnect the electrical connector 2 Remove the four screws 3 To install reverse the removal procedure SECTION 417 01 Exterior Lighting 2003 Mustang Workshop Manual ...

Page 3486: ...rim aside Remove the two retainers 2 Remove the four rear lamp nuts 3 Remove the rear lamp assembly disconnect the electrical connectors and replace the bulbs if necessary Installation 1 To install reverse the removal procedure SECTION 417 01 Exterior Lighting 2003 Mustang Workshop Manual ...

Page 3487: ......

Page 3488: ...h knob out 2 Insert a thin tool into the slot pull and remove the headlamp switch knob 3 Remove the instrument panel cluster finish panel Remove the screws and remove the finish panel 4 Remove the headlamp switch 1 Remove the screws 2 Remove the switch 3 Disconnect the electrical connectors SECTION 417 01 Exterior Lighting 2003 Mustang Workshop Manual ...

Page 3489: ...is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km 10 mi or more to relearn the strategy To install reverse the removal procedure ...

Page 3490: ...Disconnect the electrical connector 4 Remove the BPP switch Installation 1 NOTE When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km 10 mi or more to relearn the strategy To install reverse the removal procedure SECTION 417 01 Exterior Lighting 2003 Mustang Workshop Manual ...

Page 3491: ......

Page 3492: ... map dome lamp assembly rear high mount cargo lamp assembly dimmer switch door ajar switch located on the door latches rear view mirror interior lamp convertible only courtesy lamp vanity mirror lamp assembly transmission range indicator SECTION 417 02 Interior Lighting 2003 Mustang Workshop Manual ...

Page 3493: ...ompartment lid ajar circuit or if the dome lamp is switched on by means of the dome lamp circuit When the GEM detects that the ignition switch is in the RUN ACC or START positions the battery saver feature is disabled The battery saver timer for the demand lamps is reset when the GEM detects that the ignition switch is in the OFF or key out positions or when the GEM detects any one of the followin...

Page 3494: ...ved from the OFF position to either the RUN ACC or START positions Demand Lighting The GEM does not provide any special features to the demand lighting group with the exception of providing a power source when the battery saver feature is active The demand lighting group consists of the luggage compartment lamp the driver and passenger vanity mirror lamps and the map lamps Illuminated Entry with R...

Page 3495: ...the GEM 7 If the DTCs retrieved are related to the concern go to GEM Diagnostic Trouble Code DTC Index to continue diagnostics 8 If no DTCs related to the concern are retrieved proceed to Symptom Chart to continue diagnostics GEM Diagnostic Trouble Code DTC Index Visual Inspection Chart Mechanical Electrical Switch es CJB Fuses 7 20A 32 15A 39 5A Wiring harness Connections Lamps Circuitry GEM Diag...

Page 3496: ...on 501 16 B1448 Wiper Park Sense Circuit Short to Battery GEM REFER to Section 501 16 B1450 Wiper Wash Delay Switch Circuit Failure GEM REFER to Section 501 16 B1453 Wiper Wash Delay Switch Circuit Short to Ground GEM REFER to Section 501 16 B1458 Wiper Washer Pump Motor Relay Circuit Failure GEM REFER to Section 501 16 B1460 Wiper Washer Pump Motor Relay Coil Circuit Short to Battery GEM REFER to...

Page 3497: ...Chart Condition Possible Sources Action No communication with the generic electronic module CJB Fuse 39 5A GEM Circuitry GO to Pinpoint Test A The courtesy lamps are inoperative CJB Fuse 7 20A Door ajar switch es Courtesy lamp assemblies Circuitry GEM Ignition Switch Headlamp Switch GO to Pinpoint Test B The demand lighting is inoperative CJB Fuse 7 20A Circuitry GEM Door ajar switch es Demand lam...

Page 3498: ... a new GEM PINPOINT TEST A NO COMMUNICATION WITH THE GENERIC ELECTRONIC MODULE Test Step Result Action to Take CAUTION Use the correct probe adapter s when making measurements Failure to use the correct probe adapter s may damage the connector A1 GENERIC ELECTRONIC MODULE GEM POWER SUPPLY Key in OFF position Disconnect Generic Electronic Module GEM C201a Disconnect GEM C201b Key in ON position Usi...

Page 3499: ... the PID values agree with the ignition switch positions Yes GO to B2 No For key in ignition concerns REFER to Section 413 09 B2 CHECK THE DOOR AJAR INPUT TO THE GEM Monitor the GEM PID D_DOOR and P_DOOR while opening and closing the driver and passenger doors Do the GEM PIDS D_DOOR and P_DOOR agree with the driver and passenger door positions Yes GO to B3 No REFER to Section 413 09 B3 CHECK THE D...

Page 3500: ... B7 B7 CHECK THE GEM FOR AN INTERNAL FAULT Trigger the GEM active command COURTESYL ON then OFF Can an audible click be heard coming from the GEM while triggering the active command COURTESYL ON Yes GO to B8 No INSTALL a new GEM For additional information REFER to Section 419 10 REPEAT the self test CLEAR the DTCs B8 CHECK CIRCUIT 1034 BK WH FOR VOLTAGE Disconnect the dome lamp C929 coupe or map l...

Page 3501: ... DTCs B11 CHECK CIRCUIT 1205 BK FOR OPEN Measure the resistance between dome map lamp C929 coupe Pin 2 or map lamp C978 convertible Pin 1 Circuit 1205 BK harness side and ground Is the resistance less than 5 ohms Yes INSTALL a new dome map lamp assembly For additional information REFER to Lamp Assembly Map Dome No REPAIR the circuit REPEAT the self test CLEAR the DTCs B12 CHECK CIRCUIT 1034 BK WH ...

Page 3502: ... Section 419 10 REPEAT the self test CLEAR the DTCs No REPAIR the circuit REPEAT the self test CLEAR the DTCs B15 CHECK CIRCUIT 706 GY FOR SHORT TO BATTERY Measure the voltage between GEM C201e Pin 21 Circuit 706 GY harness side and ground Is the voltage greater than 10 volts Yes REPAIR the circuit REPEAT the self test CLEAR the DTCs No INSTALL a new GEM For additional information REFER to Section...

Page 3503: ...419 10 REPEAT the self test CLEAR the DTCs No REPAIR the circuit REPEAT the self test CLEAR the DTCs B19 CHECK CIRCUIT 486 BN WH FOR AN OPEN MONITOR GEM PID DECKLID Disconnect Luggage Compartment Solenoid C430 Monitor the GEM PID DECKLID Connect a 10A fused jumper between luggage compartment solenoid C430 Pin 3 Circuit 486 BN WH harness side and ground Does the GEM PID DECKLID indicate AJAR with t...

Page 3504: ...D LAMPS Turn on both map lamps by depressing the map lamp switches Turn on both vanity mirror lamps Open the luggage compartment lid Do any of the lamps illuminate Yes GO to C8 No GO to C2 C2 CHECK IGNITION STATES Monitor the GEM PIDS IGN_KEY IGN_A IGN_S and IGN_R while cycling the ignition switch through the OFF ACC RUN START and key out positions Do the PID values agree with the ignition switch ...

Page 3505: ... on both vanity mirror lamps Open the luggage compartment lid Disconnect GEM C201c Connect a fused jumper 20A between GEM C201c Pin 4 Circuit 705 LG OG harness side and battery positive terminal Do the demand lamps illuminate Yes GO to C7 No REPAIR the circuit REPEAT the self test CLEAR the DTCs C7 CHECK CIRCUIT 1006 DG WH FOR OPEN NOTE Verify battery voltage at CJB Fuse 7 20A before carrying out ...

Page 3506: ...stance less than 5 ohms Yes INSTALL a new demand lamp assembly REPEAT the self test CLEAR the DTCs No REPAIR the circuit in question REPEAT the self test CLEAR the DTCs Test Step Result Action to Take D1 CHECK THE REMOTE TRANSMITTER INPUT TO THE GEM Remove the ignition key from the ignition Depress the lock and then the unlock buttons on the remote transmitter Do the doors lock when the lock butto...

Page 3507: ...NSTALL a new GEM For additional information REFER to Section 419 10 REPEAT the self test CLEAR the DTCs No GO to E2 E2 CHECK CIRCUITS 1034 BK WH AND 705 LG OG FOR SHORT TO BATTERY Disconnect GEM C201c Measure the voltage between GEM C292 Pin 3 Circuit 1034 BK WH harness side and ground and between GEM C292 Pin 4 Circuit 705 LG OG harness side and ground Is the voltage greater than 10 volts Yes REP...

Page 3508: ......

Page 3509: ...ve the lamp assembly Disconnect the electrical connectors Installation 1 NOTE When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km 10 mi or more to relearn the strategy To install reverse the removal procedure SECTION 417 02 Interior Lighting 2003 Mustang Workshop Manual ...

Page 3510: ......

Page 3511: ...PECIFICATIONS SECTION 417 04 Daytime Running Lamps 2003 Mustang Workshop Manual Torque Specifications Description Nm lb in Battery ground cable screw 8 71 Daytime running lamps control module bolts 9 80 ...

Page 3512: ...ng Lamps DRL The daytime running lamp DRL system consists of a daytime running lamp module and bracket assembly 15A270 The module is located on the front bumper reinforcement SECTION 417 04 Daytime Running Lamps 2003 Mustang Workshop Manual ...

Page 3513: ...n the RUN position The DRL module remains enabled when the low beam headlamps are turned on Inspection and Verification 1 Verify the customer concern by operating the system 2 Visually inspect for obvious signs of mechanical and electrical damage 3 Verify the headlamps are operating correctly Correct any concerns before proceeding to the SECTION 417 04 Daytime Running Lamps 2003 Mustang Workshop M...

Page 3514: ...mps are on with the parking brake set Circuitry Parking brake signal switch and bracket DRL module GO to Pinpoint Test B The daytime running lamps are on with the ignition switch off Circuitry Ignition switch DRL module GO to Pinpoint Test C The low beam headlamps are on at full intensity in DRL mode Circuitry Headlamp switch DRL module GO to Pinpoint Test D The low beam headlamps are on at reduce...

Page 3515: ...or normal operation No REPAIR the circuit TEST the system for normal operation A3 CHECK VOLTAGE TO THE DRL MODULE Measure the voltage between DRL module C1030 Pin 2 Circuit 477 LB BK harness side and ground Is the voltage greater than 10 volts Yes GO to A4 No REPAIR the circuit TEST the system for normal operation A4 CHECK IGNITION SENSE INPUT Key in ON position Measure the voltage between DRL mod...

Page 3516: ...G BK Measure the voltage between DRL module C1030 Pin 5 Circuit 12 LG BK harness side and ground Is voltage indicated Yes REPAIR the circuit TEST the system for normal operation No INSTALL a new DRL module REFER to Module Daytime Running Lamps DRL TEST the system for normal operation Test Step Result Action to Take B1 CHECK THE PARKING BRAKE SWITCH Key in OFF position Disconnect Parking Brake Swit...

Page 3517: ...the system for normal operation Test Step Result Action to Take C1 CHECK THE IGNITION SWITCH INPUT TO THE DRL MODULE FOR VOLTAGE Key in OFF position Disconnect DRL Module C1030 Measure the voltage between DRL module C1030 Pin 3 Circuit 298 VT OG harness side and ground Is voltage indicated Yes GO to C2 No INSTALL a new DRL module REFER to Module Daytime Running Lamps DRL TEST the system for normal...

Page 3518: ... Step Result Action to Take D1 CHECK THE LOW BEAM HEADLAMPS INPUT Disconnect DRL Module C1030 Are the low beam headlamps still on at full intensity Yes REFER to Section 417 01 No INSTALL a new DRL module REFER to Module Daytime Running Lamps DRL TEST the system for normal operation ...

Page 3519: ...bracket assembly 15A270 1 Remove the nut 2 Disconnect the electrical connector 3 Remove the DRL module and bracket assembly Installation 1 CAUTION When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 10 miles 16 km or more to relearn the strategy To install reverse the removal proc...

Page 3520: ......

Page 3521: ...ual General Specifications Item Specification Heat shrink tube overlap mm inch 12 7 0 5 Wire insulation removal length twist side mm inch 37 2 1 5 Wire insulation removal length receiving side mm inch 19 5 0 75 Raychem SCT Heat Shrink Tubing Motorcraft part number WT 5627 ESB M99D56 A2 ...

Page 3522: ...Module Communications Network 2003 Mustang Workshop Manual Item Part Number Description 1 12A650 Powertrain Control Module PCM 2 Restraint Control Module RCM 3 10849 Hybrid Electronic Cluster HEC 4 14B205 Generic Electronic Module GEM 5 2C219 Anti Lock Brake System Traction Control ABS TC Module ...

Page 3523: ......

Page 3524: ...communications The SCP network will remain operational even with the severing of one of the bus wires Communications will also continue if one of the bus wires is shorted to ground or battery positive voltage B or if some but not all termination resistors are lost Unlike the SCP communication network the ISO 9141 communication network will not function if the wire is shorted to chassis ground or b...

Page 3525: ...ns For additional information on the PATS system refer to Section 419 01 For additional information on the instrument cluster refer to Section 413 01 Inspection and Verification 1 Verify the customer concern 2 Visually inspect for obvious signs of electrical damage 3 If the concern remains after the inspection connect diagnostic tool to the data link connector DLC located beneath the instrument pa...

Page 3526: ... RESPONSE NOT EQUIPPED REFER to Symptom Chart Symptom Chart Condition Possible Sources Action The module does not respond to the diagnostic tool anti lock brake control module Wire or connection in SCP communication network with traction control Wire or connection in ISO 9141 communication network without traction control Anti lock brake control module without traction control optional Anti lock b...

Page 3527: ...ule network communication ISO 9141 network Wire or connection in ISO 9141 communication network ISO 9141 networked modules GO to Pinpoint Test F No module network communication SCP network Wire or connection in SCP communication network SCP networked modules GO to Pinpoint Test G No module network communication no power to the diagnostic tool CJB Fuse 31 5A DLC pins Scan tool Circuitry GO to Pinpo...

Page 3528: ...Measure the resistance between in line C144 Pin 6 Circuit 914 TN OG harness side and DLC C251 Pin 2 Circuit 914 TN OG harness side Is the resistance less than 5 ohms Yes REPAIR Circuit 914 TN OG between anti lock brake control module C135 and in line C144 For additional information REFER to Communication Circuit Wiring Repair TEST the system for normal operation No GO to A5 A5 CHECK CIRCUIT 914 TN...

Page 3529: ...TWEEN DLC C251 AND IN LINE C144 FOR OPEN Disconnect In Line C144 Check in line C144 for damage repair as necessary Measure the resistance between in line C144 Pin 13 Circuit 915 PK LB harness side and DLC C251 Pin 10 Circuit 915 PK LB harness side Is the resistance less than 5 ohms Yes REPAIR Circuit 915 PK LB between anti lock brake control module C135 and in line C144 For additional information ...

Page 3530: ...Pin 24 Circuit 70 LB WH harness side and DLC C251 Pin 7 Circuit 70 LB WH harness side Is the resistance less than 5 ohms Yes INSTALL a new anti lock brake control module REFER to Section 206 09A TEST the system for normal operation No GO to A10 A10 CHECK FOR OPEN BETWEEN THE DLC C251 AND IN LINE C140 Disconnect In Line C140 Inspect in line C140 for damage repair as necessary Measure the resistance...

Page 3531: ... Inspect GEM C201e for damage repair as necessary Measure the resistance between GEM C201e Pin 6 Circuit 70 LB WH harness side and DLC C251 Pin 7 Circuit 70 LB WH harness side Is the resistance less than 5 ohms Yes INSTALL a new GEM For additional information REFER to Section 419 10 TEST the system for normal operation No REPAIR Circuit 70 LB WH between the GEM C201e and DLC C251 TEST the system f...

Page 3532: ...lt received ICM NO RESPONSE ON CKT914 BUS Yes GO to D2 No GO to D3 D2 CHECK FOR OPEN BETWEEN DLC C251 PIN 2 AND INSTRUMENT CLUSTER C220a PIN 1 CIRCUIT 914 TN OG Key in OFF position Disconnect the diagnostic tool Disconnect Instrument Cluster C220a Measure the resistance between instrument cluster C220a Pin 1 Circuit 914 TN OG harness side and DLC C251 Pin 2 Circuit 914 TN OG harness side Is the re...

Page 3533: ...75 FOR DAMAGE Key in OFF position Disconnect PCM C175 Inspect PCM C175 for damage repair as necessary Connect PCM C175 Connect the diagnostic tool Key in ON position Enter the following diagnostic mode on the diagnostic tool Diagnostic Data Link Was the result received PCM NO RESPONSE ON CKT914 BUS Yes GO to E2 No GO to E4 E2 CHECK FOR OPEN BETWEEN DLC C251 PIN 2 AND PCM C175 PIN 16 CIRCUIT 914 TN...

Page 3534: ...gnostic tool Measure the resistance between PCM C175 Pin 15 Circuit 915 PK LB harness side and DLC C251 Pin 10 Circuit 915 PK LB harness side Is the resistance less than 5 ohms Yes REFER to Powertrain Control Emissions Diagnosis PC ED manual Section 3 TEST the system for normal operation No GO to E5 E5 CHECK CIRCUIT 915 PK LB BETWEEN DLC C251 AND IN LINE C215 FOR OPEN Disconnect In Line C215 Check...

Page 3535: ...between DLC C251 Pin 7 Circuit 70 LB WH harness side and C251 Pin 4 Circuit 1205 BK and between DLC C251 Pin 7 Circuit 70 LB WH harness side and C251 Pin 16 Circuit 1047 LG RD harness side Is the voltage indicated in either measurement zero volts Yes CONNECT the GEM module C201e GO to F3 No INSTALL a new GEM For additional information REFER to Section 419 10 TEST the system for normal operation F3...

Page 3536: ... 20B TEST the system for normal operation F5 CHECK FOR THE ANTI LOCK BRAKE CONTROL MODULE Key in OFF position Connect In Line C3141 Check the vehicle for any version of the anti lock brake control module Is the vehicle equipped with any version of the anti lock brake control module with or without traction control Yes GO to F6 No GO to F7 F6 CHECK FOR SHORT TO GROUND AND POWER AT DLC C251 ANTI LOC...

Page 3537: ...LB WH harness side and C251 Pin 4 Circuit 1205 BK and between DLC C251 Pin 7 Circuit 70 LB WH harness side and C251 Pin 16 Circuit 1047 LG RD harness side Is the voltage indicated in either measurement zero volts Yes REPAIR Circuit 70 LB WH between in line C314 and in line C140 TEST the system for normal operation No REPAIR Circuit 70 LB WH between in line C140 and the anti lock brake control modu...

Page 3538: ... 915 PK LB FOR OPEN ANTI LOCK BRAKE CONTROL MODULE C135 DISCONNECTED Disconnect Anti Lock Brake Control Module C135 Measure the resistance between anti lock brake control module C135 Pin 30 Circuit 914 TN OG harness side and DLC C251 Pin 2 Circuit 914 TN OG harness side Measure the resistance between anti lock brake control module C135 Pin 29 Circuit 915 PK LB harness side and DLC C251 Pin 10 Circ...

Page 3539: ...rake control module without traction control REFER to Section 206 09A For additional information on the anti lock brake control module with traction control REFER to Section 206 09B TEST the system for normal operation G6 CHECK CIRCUIT 914 TN OG AND CIRCUIT 915 PK LB FOR THE SOURCE OF THE CONCERN IN LINE C144 DISCONNECTED Key in OFF position Disconnect In Line C144 Key in ON position Measure the v...

Page 3540: ... side Are the resistances less than 5 ohms Yes GO to G8 No REPAIR the circuit s in question between in line C215 and DLC C251 For additional information REFER to Communication Circuit Wiring Repair TEST the system for normal operation G8 CHECK CIRCUIT 914 TN OG AND CIRCUIT 915 PK LB FOR THE SOURCE OF THE CONCERN PCM C175 DISCONNECTED Key in OFF position Disconnect PCM C175 Key in ON position Measu...

Page 3541: ...DLC C251 Pin 2 Circuit 914 TN OG harness side and C251 Pin 4 Circuit 1205 BK and between DLC C251 Pin 2 Circuit 914 TN OG harness side and C251 Pin 16 Circuit 1047 LG RD harness side Measure the voltage between DLC C251 Pin 10 Circuit 915 PK LB harness side and C251 Pin 4 Circuit 1205 BK and between DLC C251 Pin 10 Circuit 915 PK LB harness side and C251 Pin 16 Circuit 1047 LG RD harness side Yes ...

Page 3542: ... side and C251 Pin 16 Circuit 1047 LG RD harness side Measure the voltage between DLC C251 Pin 10 Circuit 915 PK LB harness side and C251 Pin 4 Circuit 1205 BK and between DLC C251 Pin 10 Circuit 915 PK LB harness side and C251 Pin 16 Circuit 1047 LG RD harness side Is the voltage zero volts for any measurement Yes REPAIR the circuit s in question between in line C215 DLC C251 and the instrument c...

Page 3543: ...6 CIRCUIT 1047 LG RD Measure the voltage between DLC C251 Pin 16 Circuit 1047 LG RD harness side and ground Is the voltage greater than 10 volts Yes GO to H4 No REPAIR Circuit 1047 LG RD TEST the system for normal operation H4 CHECK THE DLC GROUND CIRCUIT 1205 BK AND CIRCUIT 651 BK YE Measure the resistance between DLC C251 Pin 4 Circuit 1205 BK harness side and ground and between DLC C251 Pin 5 C...

Page 3544: ...Is the resistance less than 5 ohms ...

Page 3545: ...n core mildly activated RMA solder not acid core solder Solder the wires 1 Install the heat shrink tube 2 Twist the wires together 3 Solder the wires together 4 NOTE Wait for the solder to cool before moving the wires Bend the wires back in a straight line SECTION 418 00 Module Communications Network 2003 Mustang Workshop Manual Special Tool s Heat Gun 107 R0300 or equivalent ...

Page 3546: ...at shrink tube over the B wire repair Overlap the heat shrink tube on both wires 6 Use the heat gun to heat the repaired area until adhesive flows out both ends of the heat shrink tube 7 Reconnect the battery ground cable ...

Page 3547: ......

Page 3548: ...or display a list of items that you will need to manually configure The diagnostic tool will program the module based on the data you enter There are three different methods that are used for module programming programmable module installation PMI calibration update programmable parameters Some modules do not support all three methods Programmable Module Installation PMI The programmable module in...

Page 3549: ...lock The VID block is used to store backup data for each programmable module as well as powertrain configuration information If the diagnostic tool cannot retrieve module option content information from the suspect module the diagnostic tool will attempt to extract backup information from the PCM s VID block The PCM VID block contains the factory settings for the configurable modules unless the PC...

Page 3550: ...Programmable Parameters Index System Programmable Parameter Items Warnings Chimes Belt Minder ...

Page 3551: ...ECTION 419 01 Anti Theft PATS 2003 Mustang Workshop Manual Torque Specifications Description Nm lb in Battery ground cable 10 89 Steering column opening reinforcement bolts 9 80 Steering column opening cover bolts 9 80 ...

Page 3552: ...d contains an antenna connected to a small electronics module During each vehicle start sequence the transceiver module reads the encoded ignition key identification code and sends the data to the instrument cluster The control functions are contained in the instrument cluster This module carries out all of the PATS functions such as receiving the identification code from the encoded ignition key ...

Page 3553: ...START PATS also blips the theft indicator every two seconds at ignition OFF to act as a visual theft deterrent The PATS is not compatible with aftermarket remote start systems which allow the vehicle to be started from outside the vehicle These systems may reduce the vehicle security level and also may cause no start issues Remote start systems must be removed before investigation of PATS related ...

Page 3554: ...ata link connector DLC located beneath the instrument panel and select the vehicle to be tested from the diagnostic tool menu If the diagnostic tool does not communicate with the vehicle check that the program card is correctly installed SECTION 419 01 Anti Theft PATS 2003 Mustang Workshop Manual Special Tool s 73III Automotive Meter 105 R0057 or equivalent Worldwide Diagnostic System WDS 418 F224...

Page 3555: ...ode DTC Index DTC Description Source Action B1202 Fuel Sender Open Circuit ICM REFER to Section 413 01 B1204 Fuel Sender Short to Ground ICM REFER to Section 413 01 B1213 Anti Theft Number of Programmed Keys is Below Minimum ICM GO to Pinpoint Test D B2103 or B1232 Antenna Not Connected Defective Transceiver ICM GO to Pinpoint Test E B1317 Battery Voltage High ICM REFER to Section 414 00 B1318 Bat...

Page 3556: ...cator is always never on no three second theft indicator prove out Instrument cluster Theft indicator GO to Pinpoint Test B The vehicle does not start theft indicator proves out for three seconds as normal Less than two keys programmed to the system Transceiver not connected defective Circuitry Transceiver internal antenna damaged NON PATS key damaged key or no code received Partial key read of PA...

Page 3557: ...ey in OFF position Disconnect Instrument Cluster C220b Measure voltage between instrument cluster C220b Pin 10 Circuit 729 RD WH harness side and ground Is the voltage greater than 10 volts Yes GO to A2 No REPAIR the circuit REPEAT the self test CLEAR the DTCs A2 CHECK THE RUN POWER SUPPLY TO THE INSTRUMENT CLUSTER Key in ON position Measure the voltage between instrument cluster C220b Pin 11 Circ...

Page 3558: ...ey in OFF position Measure the resistance between instrument cluster C220b Pin 20 Circuit 397 BK WH harness side and ground Is the resistance less than 5 ohms Yes GO to A5 No REPAIR the circuit REPEAT the self test CLEAR the DTCs A5 CHECK GROUND CIRCUIT 1205 BK FOR OPEN Measure the resistance between instrument cluster C220b Pin 1 Circuit 1205 BK harness side and ground Is the resistance less than...

Page 3559: ... greater than 10 000 ohms in one direction and 10 20 ohms in the other direction Yes INSTALL a new instrument cluster for additional information REFER to Section 413 01 CYCLE the ignition to RUN using two encoded ignition keys Go To Pinpoint Test J to initialize the module REPEAT the self test CLEAR the DTCs No INSTALL a new anti theft LED For additional information REFER to Section 413 01 REPEAT ...

Page 3560: ...tic tool Clear Continuous DTCs Enter the following diagnostic mode on the diagnostic tool Instrument Cluster On Demand Self Test Is DTC U1147 retrieved Yes INSTALL a new instrument cluster for additional information REFER to Section 413 01 CYCLE the ignition to RUN using two encoded ignition keys Go To Pinpoint Test J to initialize the module REPEAT the self test CLEAR the DTCs If DTC U1147 is sti...

Page 3561: ...ment Cluster On Demand Self Test to verify all codes have been cleared REPEAT the self test CLEAR the DTCs No If the theft indicator is on continuously REPEAT TEST STEP D3 with a second new encoded ignition key If the theft indicator is flashing RETRIEVE DTCs stored for the new fault and REPAIR the other DTC s retrieved Test Step Result Action to Take E1 INSPECT THE PATS TRANSCEIVER FOR CORRECT IN...

Page 3562: ...eved system is OK F2 PROGRAM A NEW ENCODED IGNITION KEY Key in OFF position NOTE Check to make sure the customer and replacement encoded ignition keys are approved Ford encoded PATS ignition keys Unapproved PATS keys do not always operate correctly over different temperature ranges encoded ignition keys from Rotunda Ilco or Strattec are approved encoded ignition keys Cut a new encoded ignition key...

Page 3563: ...and On Demand Self Tests Is DTC B1601 recorded Yes GO to G2 No System is OK CHECK all customer encoded ignition keys with Instrument Cluster On Demand Self Test to verify all other encoded ignition keys are programmed G2 CHECK FOR PROGRAMMED ENCODED IGNITION KEYS MONITOR THE INSTRUMENT CLUSTER PID NUMKEYS Monitor the instrument cluster PID NUMKEYS Does the instrument cluster PID NUMKEYS display 8 ...

Page 3564: ...e vehicle REPEAT the self test CLEAR the DTCs No System is OK If other DTCs are retrieved REFER to Instrument Cluster Module Diagnostic Trouble Code DTC Index Test Step Result Action to Take NOTE Large metallic objects electronic debit transponder devices or a second key on the same key ring as the PATS ignition key may cause vehicle starting problems and record DTCs under certain conditions If a ...

Page 3565: ...rs Guide H3 INSTALL A NEW PATS TRANSCEIVER Key in OFF position Install a new PATS transceiver for additional information refer to Module Passive Anti Theft Transceiver Key in ON position Enter the following diagnostic mode on the diagnostic tool Instrument Cluster On Demand Self Test Are any DTCs retrieved Yes REFER to Instrument Cluster Diagnostic Trouble Code DTC Index No System is OK Test Step ...

Page 3566: ...CUIT 1216 GY OG Connect PATS Transceiver C252 Key in ON position Measure the voltage by back probing between PATS transceiver C252 Pin 3 Circuit 1216 GY OG harness side and ground Is the voltage greater than 9 volts Yes GO to I6 No GO to I5 I5 CHECK THE PATS TRANSCEIVER RECEIVE CIRCUIT FOR SHORT TO GROUND CIRCUIT 1216 GY OG Key in OFF position Disconnect PATS Transceiver C252 Measure the resistanc...

Page 3567: ...harness side and instrument cluster C220a Pin 7 Circuit 1216 GY OG harness side Is the resistance less than 5 ohms Yes GO to I7 No REPAIR Circuit 1216 GY OG CLEAR the DTCs TEST the system for normal operation I7 CHECK THE PATS TRANSCEIVER TRANSMIT CIRCUIT FOR VOLTAGE CIRCUIT 1215 WH LG Key in OFF position Connect PATS Transceiver C252 Connect Instrument Cluster C220a Key in ON position Measure the...

Page 3568: ...ent cluster for additional information REFER to Section 413 01 CYCLE the ignition to RUN using two encoded ignition keys GO to Pinpoint Test J to initialize the module REPEAT the self test CLEAR the DTCs If the circuit is not OK REPAIR Circuit 1215 WH LG REPEAT the self test CLEAR the DTCs I10 CHECK THE PATS SYSTEM WITH A NEW PATS TRANSCEIVER INSTALLED Key in OFF position Install a new PATS transc...

Page 3569: ...cluster Use diagnostic card for PCM Active Command Keep Alive Memory Reset Key in OFF position Select FSF card PARAMETER RESET command for PCM Key in ON position Turn the ignition switch to RUN for three seconds Enter the following diagnostic mode on the diagnostic tool Clear Continuous DTCs Key in OFF position Enter the following diagnostic mode on the diagnostic tool Retrieve Continuous DTCs Is ...

Page 3570: ...key in the run position for thirty seconds Key in OFF position Start the vehicle Does the vehicle start Yes System is OK No GO to K3 K3 RETRIEVE THE INSTRUMENT CLUSTER DTCS Enter the following diagnostic mode on the diagnostic tool Clear Continuous DTCs Key in OFF position Key in ON position Key in OFF position Enter the following diagnostic mode on the diagnostic tool Instrument Cluster On Demand...

Page 3571: ......

Page 3572: ... remaining keys are with the customer and are not available with the vehicle then instruct the customer to refer to the Owners Guide under the Programming Spare SecuriLock North America Safeguard U K or PATS for all other markets Keys Procedure for instructions on programming the remaining keys 1 Turn the ignition switch from OFF to RUN 2 Enter diagnostic tool Follow the SECURITY ACCESS PROCEDURE ...

Page 3573: ......

Page 3574: ...and perform pinpoint tests as required NOTE A maximum of eight ignition keys can be programmed to a passive anti theft system PATS equipped vehicle Use PID NUMKEYS to determine how many keys are programmed to the vehicle NOTE If the steps are not performed as outlined the programming procedure will end NOTE Ignition keys must have correct mechanical key cut for the vehicle and must be a PATS encod...

Page 3575: ... maintain the ignition switch in RUN for 1 second 6 If it is desired to program additional key s repeat the key programming procedure from the beginning ...

Page 3576: ... key programming switch state can be viewed by instrument cluster PID SPARE_KY 1 Insert a programmed ignition key into the ignition lock cylinder and turn the ignition switch to RUN 2 Enter diagnostic tool Follow the SECURITY ACCESS PROCEDURE For additional information refer to Security Access Procedure to obtain security access 3 NOTE The default setting on delivery of all new vehicles is ENABLE ...

Page 3577: ......

Page 3578: ...all stored key codes first The number of keys programmed into the system can be determined using the PID NUMKEYS 1 Turn the ignition switch from the OFF position to the RUN position using the new unprogrammed ignition key 2 Enter diagnostic tool using the Ford Service Function FSF card and enter the appropriate instrument cluster Follow Security Access to obtain security access For additional info...

Page 3579: ......

Page 3580: ...and Index NOTE Select only the commands required by the appropriate pinpoint test 1 From diagnostic tool Using the Ford Service Function FSF card select the appropriate instrument cluster Enter SECURITY ACCESS PROCEDURE This procedure will take 10 minutes to perform during which the ignition switch must be in RUN and the diagnostic tool must be connected to the vehicle 2 After the 10 minute securi...

Page 3581: ......

Page 3582: ...rt the ignition key into the ignition switch lock cylinder and turn to the RUN position 2 Insert a punch in the access hole of the steering column and press the release tab while pushing out the ignition switch lock cylinder 3 Unscrew the tilt wheel handle and shank and remove 4 Remove the instrument panel steering column opening cover 1 Remove the screws 2 Remove the LH instrument panel steering ...

Page 3583: ...nt panel steering column opening cover reinforcement 1 Remove the bolts 2 Remove the instrument panel steering column opening cover reinforcement 7 NOTE The steering wheel has been removed for clarity Remove the anti theft transceiver module 1 Remove the screw from the bottom of the transceiver module 2 NOTE Only apply pressure or leverage below the key cylinder lower rib Disconnect the electrical...

Page 3584: ...y disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km 10 miles or more to relearn the strategy To install reverse the removal procedure ...

Page 3585: ......

Page 3586: ...SPECIFICATIONS SECTION 419 10 Multifunction Electronic Control Modules 2003 Mustang Workshop Manual Torque Specifications Description Nm lb in Battery ground cable bolt 7 10 62 89 ...

Page 3587: ...on control module on this vehicle The GEM controls the following functions warning chimes and warning lamps one touch down window windshield washers and wipers battery saver illuminated entry with keyless remote entry interior lighting SECTION 419 10 Multifunction Electronic Control Modules 2003 Mustang Workshop Manual ...

Page 3588: ...cerns refer to Section 417 02 For one touch window concerns refer to Section 501 11 For wiper washer control and interval timer concerns refer to Section 501 16 For keyless entry and power door lock concerns refer to Section 501 14B For anti theft concerns refer to Section 419 01 SECTION 419 10 Multifunction Electronic Control Modules 2003 Mustang Workshop Manual ...

Page 3589: ... 1 Remove the five electrical connectors 2 Release the locking tab and slide the module off the bracket Installation 1 NOTE When the battery 10655 is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 10 mile s 16 km or more to relearn the strategy To install reverse the removal procedure SECTION 41...

Page 3590: ......

Page 3591: ...pecifications Item Specification Adhesives Weatherstrip and Rubber Adhesive E8AZ 19552 A ESB M2G14 A Lubricants Silicone Lubricant C0AZ 19553 AA ESR M13P4 A Sealers HB Fuller E709 19554 B ESB M4G162 A 3M Strip Caulk Black 051135 08578 ESB M4G32 A Silicone Gasket and Sealant F7AZ 19554 EA WSK M2G343 A4 ...

Page 3592: ...he body Is a unibody open cowl structure Is constructed of a lightweight all steel material with removable bolted hood 16612 front fenders 16005 doors and luggage compartment lid SECTION 501 00 Body System General Information 2003 Mustang Workshop Manual ...

Page 3593: ...ed felt Insulation is installed Under the roof panel 50202 Above and below the instrument panel 04304 On the cowl sides Over the front and rear floor areas On a Coupe in the B and C pillar sections Under the hood SECTION 501 00 Body System General Information 2003 Mustang Workshop Manual ...

Page 3594: ... a gasket Weatherstrip Adhesive Weatherstrip and Rubber Adhesive E8AZ 19552 A or equivalent meeting Ford specification ESB M2G14 A Is a quick drying strong adhesive designed to hold weatherstripping onto all body panels and surrounding metal Silicone Lubricant Silicone Lubricant C0AZ 19553 AA meeting Ford specification ESR M13P4 A Is used to keep the door and the window weatherstrip pliable and so...

Page 3595: ......

Page 3596: ...n ducts open Most wind noise leaks will occur at the door and window seals or at the sheet metal joints in the door or the door opening Symptom Chart SECTION 501 00 Body System General Information 2003 Mustang Workshop Manual Symptom Chart Condition Possible Sources Action Dust and Water Leaks Body sealer missing Opening in weldings or body joints Components not fully installed Components missing ...

Page 3597: ...43 A4 ROAD TEST Rattles Loose objects in wells pillars and quarter panels Misalignment if tightening bolts does not eliminate rattle Weatherstripping and or anti squeak material CHECK doors by carefully STRIKING underside of door with a rubber mallet LISTEN for loose objects in door REPAIR TIGHTEN body bolts and screws ADJUST the alignment of the doors or panels APPLY additional sealer INSTALL in ...

Page 3598: ...s Description Nm lb ft lb in Hood latch support screws 12 9 Hood latch retaining screws 12 9 Hood latch control handle and cable retaining screws 3 27 Hood latch support nuts 10 89 Fender bolts 12 9 Grille opening panel bolts 3 27 Rear hood hinge to body bolts 9 80 Front hood hinge to body bolts 13 10 ...

Page 3599: ... The front end body panel components consist of the following air deflectors cowl grille fenders fender splash shields hood hood hinges hood weatherstrip radiator grille opening panel SECTION 501 02 Front End Body Panels 2003 Mustang Workshop Manual ...

Page 3600: ...ase 4 Disconnect the antenna cable from the antenna base 2 Remove the front bumper cover For additional information refer to Section 501 19 3 Remove the screw the two pin type retainers and the front rocker panel moulding 4 Remove the fender splash shield screw 5 NOTE Position the fender splash shield aside SECTION 501 02 Front End Body Panels 2003 Mustang Workshop Manual ...

Page 3601: ...hrough the door opening remove the inner fender bolts 7 Remove the radiator grille opening panel to fender bolts 8 Remove the upper bolts and the fender 9 NOTE On the RH fender feed the antenna cable through the fender opening To install reverse the removal procedure ...

Page 3602: ...Check the fender alignment and adjust as needed ...

Page 3603: ...tion 1 Remove the front bumper cover For additional information refer to Section 501 19 2 Remove the eight bolts four on each side and the radiator grille opening panel 3 To install reverse the removal procedure SECTION 501 02 Front End Body Panels 2003 Mustang Workshop Manual ...

Page 3604: ...m of the door to the rocker panel 3 0 7 0 mm 0 118 0 275 in parallel top to bottom within 2 0 mm 0 08 in Door clearance front and rear of the door to the body 3 0 7 0 mm 0 118 0 275 in parallel with the body opening within 1 0 mm 0 04 in Door flushness door to the front fender 1 0 0 00 mm 0 04 0 00 in Torque Specifications Description Nm lb ft lb in Door latch striker plate bolts 25 18 Door hinge ...

Page 3605: ......

Page 3606: ...strips hood hood Cobra with heat extractor scoops hood Mach I with shaker opening hood heat extractor scoops Cobra hood hinges hood support rod hood weatherstrip luggage compartment lid luggage compartment lid hinges luggage compartment lid hydraulic lifts luggage compartment lid latch striker luggage compartment lid weatherstrip SECTION 501 03 Body Closures 2003 Mustang Workshop Manual ...

Page 3607: ...er trim panel 2 Position the electrical connectors aside 3 Loosen the lower front door hinge to body nut enough to permit movement 4 Remove the fender For additional information refer to Section 501 02 5 Mark the position of the upper and lower front door hinges to the body to use as reference points 6 Loosen the four upper and lower front door hinge to body bolts enough to permit movement SECTION...

Page 3608: ...that the door can be closed easily and fits tightly Tighten the front door hinge to body bolts 9 Tighten the front door hinge to body nut 10 Install the electrical connectors 11 Install the A pillar lower trim panel 12 Install the fender For additional information refer to Section 501 02 ...

Page 3609: ......

Page 3610: ...dels 1 Mark the position of the front door hinges to the front door to use as reference points 2 Loosen the front door hinge to front door bolts enough to permit movement 3 Adjust the front door alignment to specification 4 NOTE After aligning the door verify that the door can be closed easily and fits tightly Tighten the front door hinge to front door bolts SECTION 501 03 Body Closures 2003 Musta...

Page 3611: ......

Page 3612: ...osed easily and fits tightly 1 Loosen the door latch striker plate bolts 2 Reposition the door latch striker plate from side to side or up and down as necessary 3 Tighten the door latch striker plate bolts 4 Check the adjustment Repeat the procedure as necessary SECTION 501 03 Body Closures 2003 Mustang Workshop Manual ...

Page 3613: ......

Page 3614: ...nnect the necessary electrical connectors to remove the harness and grommet from the door 3 NOTE This procedure requires an assistant NOTE Mark the location of the door hinge on the door Remove bolts and the door Installation 1 To install reverse the removal procedure SECTION 501 03 Body Closures 2003 Mustang Workshop Manual ...

Page 3615: ......

Page 3616: ...ctrical connector 2 Remove the lift cylinder 3 Remove the luggage compartment lid hinge bolts 4 NOTE Remove the sealer around the luggage compartment lid hinge if necessary Remove the nuts and the luggage compartment lid hinge SECTION 501 03 Body Closures 2003 Mustang Workshop Manual ...

Page 3617: ...Installation 1 NOTE If removed apply new sealer To install reverse the removal procedure ...

Page 3618: ......

Page 3619: ...kshop Manual General Specifications Item Specification Adhesives Headliner Adhesive F1VY 19562 A WSS M2G355 B Torque Specifications Description Nm lb ft Safety belt guide bolt 40 30 Safety belt anchor bolt 40 30 Rear seat backrest bolster bolts 11 8 Rear seat backrest bolts 11 8 ...

Page 3620: ...trim panels door trim panels headliner coupe package tray trim panel coupe quarter trim panels upper quarter trim panels coupe scuff plates sun visors tether anchor covers coupe windshield side garnish mouldings SECTION 501 05 Interior Trim and Ornamentation 2003 Mustang Workshop Manual ...

Page 3621: ...r Position the window regulator switch plate 14527 aside 1 Pull at the service notch 2 Lift to release the clip at the rear edge 2 Remove the window regulator switch plate 1 Disconnect the power mirror electrical connector 2 Remove the screws and the window regulator switch plate 3 Remove the door latch release handle cup 22634 SECTION 501 05 Interior Trim and Ornamentation 2003 Mustang Workshop M...

Page 3622: ...4 Remove the cover Vehicles with Mach 460 Premium Sound System 5 Remove the screw and the speaker Disconnect the electrical connector All vehicles 6 Remove the screws ...

Page 3623: ...7 Remove the door trim panel 23942 1 Remove the pin type retainer 2 Lift up the door trim panel to remove Installation 1 To install reverse the removal procedure ...

Page 3624: ...nformation refer to Trim Panel Upper Quarter in this section 2 Remove the scuff plate 3 Remove the pin type retainers 4 Lower the rear seat backrests 5 Remove the bolts and the rear seat backrest bolster 6 Remove the quarter trim panel pin type retainers SECTION 501 05 Interior Trim and Ornamentation 2003 Mustang Workshop Manual ...

Page 3625: ...7 Remove the lower quarter trim panel 8 To install reverse the removal procedure ...

Page 3626: ...ll down position 2 Remove the rear seat cushion 3 Remove the two bolts and the rear seat backrest 4 Remove the scuff plate 5 Using the special tool remove the front safety belt anchor bolt SECTION 501 05 Interior Trim and Ornamentation 2003 Mustang Workshop Manual Special Tool s Safety Belt Bolt Bit 501 010 T77L 2100 A ...

Page 3627: ...6 Remove the pin type retainers 7 Remove the speaker grille 8 Remove the pin type retainers and the quarter trim panel 9 To install reverse the removal procedure ...

Page 3628: ......

Page 3629: ... seat cushion 2 Using the special tool remove the rear safety belt anchor bolt 3 Remove the screw and the coat hook 4 Open the front safety belt guide bolt cover SECTION 501 05 Interior Trim and Ornamentation 2003 Mustang Workshop Manual Special Tool s Safety Belt Bolt Bit 501 010 T77L 2100 A ...

Page 3630: ...5 Using the special tool remove the front safety belt guide bolt 6 Remove the upper quarter trim panel 7 To install reverse the removal procedure ...

Page 3631: ......

Page 3632: ...r safety belt guide cover is damaged or the cover does not remain closed install a new shoulder safety belt guide cover Open the safety belt cover 3 Using the special tool remove the front safety belt guide bolt and position the safety belt guide aside SECTION 501 05 Interior Trim and Ornamentation 2003 Mustang Workshop Manual Special Tool s Torx Bit Safety Belt Bolt 501 010 T77L 2100 A ...

Page 3633: ... upper trim panel aside 5 Lower the seat backrests 6 Remove the bolts and the rear seat backrest bolster 7 Remove the two pin type retainers and the package tray trim panel 8 To install reverse the removal procedure ...

Page 3634: ......

Page 3635: ...l Upper Quarter in this section 2 Remove the two windshield side garnish mouldings 3 Remove the two sun visors 1 Remove the six screws 2 Position the sun visors aside If equipped disconnect the electrical connectors 4 Remove the two pin type retainers SECTION 501 05 Interior Trim and Ornamentation 2003 Mustang Workshop Manual ...

Page 3636: ... Installation 1 CAUTION Folding the headliner will result in damage to the headliner Install the headliner 1 Position the headliner Apply Headliner Adhesive F1VY 19562 A meeting Ford specification WSS M2G355 B to the headliner using the existing pattern 2 Connect the electrical connector 3 Engage the wiring harness locators 2 Install the two pin type retainers 3 Install the two sun visors ...

Page 3637: ...ipped connect the electrical connectors 2 Install the screws 4 Install the two windshield side garnish mouldings 5 Install the two upper quarter trim panels For additional information refer to Trim Panel Upper Quarter in this section ...

Page 3638: ...erior Trim and Ornamentation 2003 Mustang Workshop Manual Torque Specifications Description Nm lb in Hood scoop 3 27 Radiator grille screws 6 53 Rear spoiler nuts screws 9 80 Roof side moulding screws 3 27 Roof side moulding nuts 3 27 ...

Page 3639: ...im and ornamentation consists of the following components body side scoop hood scoop if equipped front spoiler Mach 1 radiator grille rear spoiler if equipped rocker panel moulding roof side moulding SECTION 501 08 Exterior Trim and Ornamentation 2003 Mustang Workshop Manual ...

Page 3640: ...stallation 1 Remove the front bumper cover For additional information refer to Section 501 19 2 Remove the screws and the radiator grille 3 To install reverse the removal procedure SECTION 501 08 Exterior Trim and Ornamentation 2003 Mustang Workshop Manual ...

Page 3641: ... and Installation 1 Remove the weatherstrip 2 Remove the exterior roof side moulding screws 3 Remove the interior roof side moulding screws 4 Remove the roof side moulding screw SECTION 501 08 Exterior Trim and Ornamentation 2003 Mustang Workshop Manual ...

Page 3642: ...the two clips 2 NOTE Grasp the roof side moulding and lift up to release the money clip Remove the money clip 6 Remove the upper quarter trim panel For additional information refer to Section 501 05 7 Remove the nuts and the roof side moulding ...

Page 3643: ...8 To install reverse the removal procedure ...

Page 3644: ...val 1 Remove the front rocker panel moulding screw 2 Remove the strip 3 Remove the rear rocker panel moulding screw 4 Remove the pin type retainers and the rocker panel moulding SECTION 501 08 Exterior Trim and Ornamentation 2003 Mustang Workshop Manual ...

Page 3645: ...Installation 1 To install reverse the removal procedure ...

Page 3646: ...igh mounted stoplamp electrical connector 3 Remove the screws and the nuts 4 CAUTION Use care not damge the pin type retainers and pin type retainer seals during removal Release the spoiler from the two pin type retainers in an upward motion SECTION 501 08 Exterior Trim and Ornamentation 2003 Mustang Workshop Manual ...

Page 3647: ...5 To install reverse the removal procedure Inspect the pin type retainer seals Install new pin type retainer seals if damaged ...

Page 3648: ...ECIFICATIONS SECTION 501 09 Rear View Mirrors 2003 Mustang Workshop Manual Torque Specifications Description Nm lb ft lb in Exterior rear view mirror nuts 12 9 Exterior rear view mirror motor screws 7 62 ...

Page 3649: ... the following components exterior rear view mirror exterior rear view mirror control exterior rear view mirror glass exterior rear view mirror motor interior rear view mirror exterior rear view mirror Cobra manual folding SECTION 501 09 Rear View Mirrors 2003 Mustang Workshop Manual ...

Page 3650: ...y the symptom and refer to the Symptom Chart Symptom Chart Refer to the Wiring Diagrams for connector numbers stated in the pinpoint tests SECTION 501 09 Rear View Mirrors 2003 Mustang Workshop Manual Special Tool s 73III Automotive Meter 105 R0057 or equivalent Flex Probe Kit 105 R025B or equivalent Visual Inspection Chart Mechanical Electrical Exterior rear view mirrors Interior rear view mirror...

Page 3651: ...on to Take A1 CHECK CIRCUIT 326 WH VT Disconnect Exterior Rear View Mirror Control C527 Measure the voltage between exterior rear view mirror control C527 pin 1 circuit 326 WH VT harness side and ground Is the voltage greater than 10 volts Yes GO to A2 No REPAIR the circuit TEST the system for normal operation A2 CHECK CIRCUIT 1205 BK FOR AN OPEN Measure the resistance between exterior rear view m...

Page 3652: ...ror C516 pin C circuit 542 YE harness side and ground or between passenger exterior rear view mirror C622 pin C circuit 542 YE harness side and ground Select the inoperative side and actuate the exterior rear view mirror control to the down position then the right position Are the voltages greater than 10 volts Yes GO to B3 No GO to B2 B2 CHECK CIRCUIT 542 YE FOR AN OPEN Disconnect Exterior Rear V...

Page 3653: ...ance between exterior rear view mirror control C527 pin 3 circuit 541 DB harness side and driver exterior rear view mirror C516 pin B circuit 541 DB harness side Is the resistance less than 5 ohms Yes INSTALL a new exterior rear view mirror control REFER to Switch Exterior Rear View Mirror Control in this section TEST the system for normal operation No REPAIR the circuit TEST the system for normal...

Page 3654: ...nnect Exterior Rear View Mirror Control C527 Measure the resistance between exterior rear view mirror control C527 pin 4 circuit 540 RD harness side and driver exterior rear view mirror C516 pin A circuit 540 RD harness side Is the resistance less than 5 ohms Yes INSTALL a new exterior rear view mirror control REFER to Switch Exterior Rear View Mirror Control in this section TEST the system for no...

Page 3655: ... rear view mirror harness side while actuating the exterior rear view mirror control according to the following chart Circuit Exterior rear view mirror control position Measure for voltage or resistance Driver 540 RD Left Greater than 10 volts 540 RD Right Less than 5 ohms 541 DB Up Greater than 10 volts 541 DB Down Less than 5 ohms 542 YE Left Less than 5 ohms 542 YE Right Greater than 10 volts 5...

Page 3656: ...uating the exterior rear view mirror control according to the following chart Pin Circuit Exterior rear view mirror control position Measure for resistance or voltage 6 542 YE Left Less than 5 ohms 6 542 YE Right Greater than 10 volts 6 542 YE Up Less than 5 ohms 6 542 YE Down Greater than 10 volts Driver side selected 4 540 RD Left Greater than 10 volts 4 540 RD Right Less than 5 ohms 3 541 DB Up...

Page 3657: ...Is the circuit logic OK DG volts 8 543 DG Right Less than 5 ohms 7 544 VT Up Greater than 10 volts 7 544 VT Down Less than 5 ohms ...

Page 3658: ...For additional information refer to Section 501 05 2 Disconnect the power exterior rear view mirror electrical connector 3 Remove the nuts and the power exterior rear view mirror Installation 1 To install reverse the removal procedure SECTION 501 09 Rear View Mirrors 2003 Mustang Workshop Manual ...

Page 3659: ... the mirror glass pull outward and remove the mirror glass 3 Remove the mirror motor screws 4 Disconnect the mirror motor electrical connector 5 Remove the mirror motor Installation 1 NOTE When installing the mirror glass make sure it snaps completely into the mirror motor SECTION 501 09 Rear View Mirrors 2003 Mustang Workshop Manual ...

Page 3660: ...To install reverse the removal procedure ...

Page 3661: ...mage to the front door trim panel may occur Position the window regulator switch plate aside 1 Pull at service notch 2 Lift to release the clip at the rear edge 2 Remove the power exterior rear view mirror control switch Disconnect the electrical connector Installation 1 To install reverse the removal procedure SECTION 501 09 Rear View Mirrors 2003 Mustang Workshop Manual ...

Page 3662: ......

Page 3663: ...cations Description Nm lb ft lb in Front seat track to floorpan bolts and nuts 35 26 Front seat track to cushion bolts 20 15 Seat latch bolts 27 20 Seat backrest latch bolts 55 41 Front seat backrest pivot bolt 23 17 Rear seat backrest to body bolt 11 8 Safety belt guide screws 4 35 ...

Page 3664: ...power bolster and lumbar switches located on the inboard side of the seat Cobra only Seats Power Lumbar Support NOTE The pump and solenoid module are serviced as an assembly with the front seat cushion frame Cobra only The backrest bolster lumbar adjusting pads are serviced together and the cushion bolsters are serviced separately The power lumbar support system consists of SECTION 501 10 Seating ...

Page 3665: ...e repaired as individual components If a front seat backrest latch 62648 or component is non functional or damaged a new front seat backrest latch must be installed A release handle on the outboard rear corner of the seat backrest is manually operated to unlock the front seat backrest latch Rear Seat The rear seat cushion pad and frame 600A88 is retained in the following manner Pins are located on...

Page 3666: ......

Page 3667: ...s not visually evident verify the symptom GO to Symptom Chart Symptom Chart Refer to the Wiring Diagram manual for the connector numbers cited in the pinpoint tests SECTION 501 10 Seating 2003 Mustang Workshop Manual Special Tool s 73 III Automotive Meter 105 R0057 Visual Inspection Chart Mechanical Electrical Front seat track Seat at limit s of travel Battery junction box BJB Fuse Power Seat 25A ...

Page 3668: ...To Pinpoint Test E The power bolster lumbar is inoperative Cobra only Bolster lumbar pump and solenoid module Bolster lumbar seat control switches Circuitry Go To Pinpoint Test F Test Step Result Action to Take A1 CHECK CIRCUIT 566 DG Disconnect Seat Regulator Control Switch C360 Measure the voltage between seat regulator control switch C360 2 Circuit 566 DG harness side and ground Is the voltage ...

Page 3669: ...or Control TEST the system for normal operation Test Step Result Action to Take B1 CHECK THE MOTOR SUPPLY CIRCUITS Disconnect Front Height Motor C382 NOTE Make sure all connectors are connected on the seat Measure the resistance between front height motor C382 Circuit 979 RD LB harness side and ground and between front height motor C382 Circuit 990 YE LB harness side and ground Are the resistances...

Page 3670: ...E LB harness side and ground Are the resistances greater than 10 000 ohms Yes GO to B4 No REPAIR the circuit TEST the system for normal operation B4 CHECK THE UP POSITION INPUT Connect Seat Regulator Control Switch C360 Measure the voltage between front height motor C382 Circuit 979 RD LB harness side and ground Actuate the seat regulator control switch to the front UP position Is the voltage grea...

Page 3671: ...de and ground and between rear height motor C363 Circuit 982 YE LG harness side and ground Are the resistances less than 5 ohms Yes GO to C3 No GO to C2 C2 CHECK CIRCUIT 983 RD LG AND 982 YE LG FOR AN OPEN Disconnect Seat Regulator Control Switch C360 Measure the resistance between rear height motor C363 Circuit 983 RD LG harness side and seat regulator control switch C360 1 Circuit 983 RD LG harn...

Page 3672: ...en rear height motor C363 Circuit 983 RD LG harness side and ground Actuate the seat regulator control switch to the rear UP position Is the voltage greater than 10 volts Yes GO to C5 No INSTALL a new seat regulator control switch REFER to Switch Seat Regulator Control TEST the system for normal operation C5 CHECK THE DOWN POSITION INPUT Measure the voltage between rear height motor C363 Circuit 9...

Page 3673: ...d seat regulator control switch C360 3 Circuit 981 RD WH harness side then between horizontal motor C362 Circuit 980 YE WH harness side and seat regulator control switch C360 8 Circuit 980 YE WH harness side Is the resistance less than 5 ohms Yes INSTALL a new seat regulator control switch REFER to Switch Seat Regulator Control TEST the system for normal operation No REPAIR the circuit TEST the sy...

Page 3674: ...rness side and ground Actuate the seat regulator control switch to the FORWARD position Is the voltage greater than 10 volts Yes INSTALL a new seat track REFER to Seat Track TEST the system for normal operation No INSTALL a new seat regulator control switch REFER to Switch Seat Regulator Control TEST the system for normal operation Test Step Result Action to Take E1 CHECK THE LUMBAR COMPRESSOR OPE...

Page 3675: ...rcuit 51 BK WH harness side and ground Actuate the lumbar seat control switch the inflate position Is the voltage greater than 10 volts Yes INSTALL a new lumbar motor REFER to Lumbar Motor TEST the system for normal operation No GO to E5 E5 CHECK CIRCUIT 51 BK WH FOR AN OPEN Disconnect Lumbar Seat Control Switch C361 Measure the resistance between lumbar seat control switch C361 Circuit 51 BK WH h...

Page 3676: ...Yes GO to E9 No INSTALL a new lumbar motor REFER to Lumbar Motor TEST the system for normal operation E9 CHECK THE AIR FLOW FROM THE LUMBAR SEAT CONTROL SWITCH Reconnect the hose to the lumbar motor Disconnect the seat backrest lumbar adjusting hose at the lumbar seat control switch Actuate the lumbar seat control switch to the inflate position Is air felt at the seat backrest lumbar adjusting hos...

Page 3677: ...pad REFER to Lumbar Assembly TEST the system for normal operation Test Step Result Action to Take F1 CHECK THE BOLSTER LUMBAR COMPRESSOR OPERATION Actuate the bolster lumbar seat control switches Does the bolster lumbar compressor motor run Yes GO to F5 No GO to F2 F2 CHECK CIRCUIT BK FOR VOLTAGE Disconnect Bolster lumbar pump and solenoid module Measure the voltage at bolster lumbar pump and sole...

Page 3678: ...ad backrest bolster and cushion bolster Did the seat bolsters lumbar adjusting pads inflate Yes GO to F9 No For seat backrest lumbar GO to F6 For seat backrest bolster GO to F10 For seat cushion bolster GO to F14 F6 CHECK THE SEAT BACKREST LUMBAR ADJUSTING PAD Visually inspect the seat backrest lumbar adjusting pad Is the seat backrest lumbar adjusting pad damaged Yes INSTALL a new seat backrest l...

Page 3679: ...Lumbar Motor TEST the system for normal operation No INSTALL a new seat backrest lumbar adjusting pad REFER to Lumbar Assembly TEST the system for normal operation F10 CHECK THE SEAT BACKREST BOLSTER ADJUSTING PADS Visually inspect the seat backrest bolster adjusting pad Is the seat backrest bolster adjusting pad damaged Yes INSTALL a new seat backrest bolster adjusting pad REFER to Lumbar Assembl...

Page 3680: ...w seat cushion bolster adjusting pad REFER to Lumbar Assembly TEST the system for normal operation No GO to F15 F15 CHECK AIR FLOW FROM BOLSTER COMPRESSOR Disconnect the seat cushion bolster adjusting hose from the connection at the seat pivot bolt Actuate the bolster seat control switch to the inflate position while feeling for air at the connection Is air felt at the bolster motor hose connectio...

Page 3681: ...ould hold pressure for three hours After three hours is the pressure reading 32 41 kPa 4 7 psi or more INSTALL a new bolster lumbar pump and solenoid module REFER to Lumbar Motor TEST the system for normal operation No INSTALL a new seat cushion bolster adjusting pad REFER to Lumbar Assembly TEST the system for normal operation ...

Page 3682: ...ry For additional information refer to Section 414 01 2 Remove the screws and position the seat regulator control switch aside 3 Disconnect the electrical connector and remove the seat regulator control switch 4 To install reverse the removal procedure SECTION 501 10 Seating 2003 Mustang Workshop Manual ...

Page 3683: ......

Page 3684: ...on refer to Seat Front Power in this section Vehicles with standard power lumbar 2 Pull to remove the lumbar control switch 14C715 3 Disconnect the power lumbar support air hoses 4 Disconnect the lumbar seat control switch electrical connector 5 Remove the lumbar seat control switch SECTION 501 10 Seating 2003 Mustang Workshop Manual ...

Page 3685: ... screws for the power bolster and lumbar switch bezel 7 Disconnect the power lumbar switch and the bolster switches 8 Pinch the release tabs on the affected switch and push the switch through the bezel All vehicles 9 To install reverse the removal procedure ...

Page 3686: ......

Page 3687: ...this section 3 Remove the pivot bolt and seat backrest Vehicles with standard power lumbar 4 NOTE When installing the seat backrest pivot bolt make sure the hose is in front of the pivot bolt Disconnect the power lumbar air supply hose Vehicles with power bolster and lumbar 5 NOTE When installing the seat backrest pivot bolt make sure the hoses are in front of the pivot bolt Disconnect the power l...

Page 3688: ...All vehicles 6 To install reverse the removal procedure ...

Page 3689: ...n refer to Seat Front Power in this section 2 Release the J clip 3 Remove the seat backrest latch handle knob 62762 4 Pull the seat backrest trim cover up to the top of the seat 5 Remove the seat backrest foam pad from the seat backrest frame Vehicles with standard power lumbar SECTION 501 10 Seating 2003 Mustang Workshop Manual ...

Page 3690: ...mbar support air hose 7 Remove the seat backrest adjuster 65500 Vehicles with power bolster and lumbar 8 Disconnect the lumbar and bolster air supply hoses 9 Remove the two screws and remove the lumbar and bolster adjuster pad ...

Page 3691: ...All vehicles 10 To install reverse the removal procedure ...

Page 3692: ... in the safety belt guide 2 Move the seat forward 3 Remove the bolt covers and remove the seat track bolts 4 Move the seat rearward 5 Remove the seat track nuts 6 Move the seat forward 7 Disconnect the battery For additional information refer to Section 414 01 SECTION 501 10 Seating 2003 Mustang Workshop Manual ...

Page 3693: ...8 Disconnect the power seat electrical connector 9 Remove the power seat 10 To install reverse the removal procedure ...

Page 3694: ...nt seat For additional information refer to Seat Front Power in this section 2 Remove the outboard seat trim shield 3 Disconnect the electrical connector 4 Remove the seat track bolts 5 To install reverse the removal procedure SECTION 501 10 Seating 2003 Mustang Workshop Manual ...

Page 3695: ......

Page 3696: ...al information refer to Seat Front Power in this section 2 Disconnect the power seat track electrical connector 3 Remove the four seat track bolts Vehicles with standard power lumbar 4 Release the J clip 5 Remove the front seat backrest pad adjusting pump screws SECTION 501 10 Seating 2003 Mustang Workshop Manual ...

Page 3697: ...nect the power lumbar support air hose Vehicles with power bolster and lumbar 7 Remove the driver seat backrest latch For additional information refer to Latch Front Seat Backrest in this section 8 Remove the pivot bolt and seat backrest Disconnect the power lumbar support air hoses 9 Release the J clips ...

Page 3698: ...trim cover from the cushion foam pad Remove the cushion foam pad from the frame 11 NOTE The lumbar and bolster pump and solenoid module is serviced as part of the cushion frame assembly Install a new seat cushion frame assembly All vehicles 12 To install reverse the removal procedure ...

Page 3699: ...s a new unit Repair of the power seat backrest adjuster assembly components is not acceptable and should not be attempted 1 Remove the two screws and the seat backrest latch cover 2 Remove the seat backrest latch handle knob 62762 3 Release the J retainer 4 Remove the screw SECTION 501 10 Seating 2003 Mustang Workshop Manual ...

Page 3700: ...5 Remove the front seat backrest latch upper cover 62766 6 Remove the bolts and the seat backrest latch Installation 1 To install reverse the removal procedure ...

Page 3701: ......

Page 3702: ...e the seat backrest For additional information refer to Front Seat Backrest in this section Vehicles with power seat 3 Remove the screws in the power seat control switch 4 Disconnect the electrical connector and remove the power seat control switch Vehicles with standard power lumbar 5 Remove the lumbar control switch 14C715 SECTION 501 10 Seating 2003 Mustang Workshop Manual ...

Page 3703: ...rol switch electrical connector and remove the lumbar control switch Vehicles with power bolster and lumbar NOTE For vehicles with lumbar and bolster the pump and solenoid module are serviced as part of the seat cushion frame 8 Remove the power lumbar and bolster seat switch screws ...

Page 3704: ...9 Disconnect the lumbar and bolster control switches All vehicles 10 Remove the J clips 11 Remove the hog rings 12 Remove the front seat cushion cover 62900 from the front seat cushion pad 632A22 ...

Page 3705: ...ring 63100 Vehicles with power cushion bolster 14 Disconnect the hoses from the two bolster adjuster pads one shown and slide the bolster adjuster pad up and off the seat cushion frame All vehicles 15 To assemble reverse the disassembly procedure ...

Page 3706: ...ackrest For additional information refer to Front Seat Backrest in this section 2 Remove the front seat backrest head restraint 611A08 3 Remove the screws and the safety belt guide 4 Remove the front seat headrest guide rod sleeve 610A16 5 Release the J clip SECTION 501 10 Seating 2003 Mustang Workshop Manual ...

Page 3707: ...6 Remove the seat backrest latch handle knob 7 Pull the seat backrest trim cover upward 8 Remove the hog rings 9 Remove the front seat backrest trim cover 64416 from the front seat backrest pad ...

Page 3708: ...1018 from the front seat backrest foam pad Vehicles with standard power lumbar 11 Remove the seat backrest lumbar adjuster pad Vehicles with power bolster and lumbar 12 Remove the two screws and the seat backrest lumbar and bolster adjuster pad ...

Page 3709: ...All vehicles 13 To assemble reverse the disassembly procedure ...

Page 3710: ...t ALBZ 19500 5858A or equivalent ESR M2 P100 C Urethane Metal Primer Essex U 413 WSB M2G234 C Urethane Adhesive Essex U 216 WSB M2G316 B Urethane Adhesive Essex 400 HV WSB M2G316 B Urethane Glass Primer Essex U 402 WSB M5B280 C Torque Specifications Description Nm lb ft lb in Exterior weatherstrip screw 2 18 Window run screws 13 10 Window regulator motor screws 10 89 Upper regulator mounting nuts ...

Page 3711: ......

Page 3712: ... On all models the window regulator control switches are available only to the front seat passengers There are no window regulator controls for the back seat passengers Quarter window glass operations are controlled by the driver window regulator control switch Window One Touch Down The LH window one touch down feature is activated by momentarily pressing the driver window SECTION 501 11 Glass Fra...

Page 3713: ...ich is part of the front door window regulator Door window glass bracket spacers provide attachment points for the door window glass and prevent direct contact between the slider bracket and the door window glass Window Glass Quarter The rear quarter window glasses on convertible models are driven by a window regulator motor and guide assembly Window Glass Rear On the coupe the rear window upper g...

Page 3714: ...the voltage input was less than 320 ms the GEM will maintain the voltage supply to the motor down circuit The GEM will maintain the operation until seven seconds expires motor stall is detected by monitoring the current draw a voltage input is received by the GEM on either the up or down switch circuits The ground for one touch down operation does not pass through the GEM The ground is supplied th...

Page 3715: ... continuous DTCs and carry out self test diagnostics for the GEM or ICM 6 If the GEM or ICM DTCs retrieved are related to the concern go to the GEM or ICM Diagnostic Trouble Code DTC Index 7 If no DTCs related to the concern are retrieved proceed to the Symptom Chart to continue diagnostics GEM DIAGNOSTIC TROUBLE CODE DTC INDEX Visual Inspection Chart Mechanical Electrical Power window regulator W...

Page 3716: ...r Window Driver Down Circuit Short to Battery GEM GO to Pinpoint Test D for convertible or Pinpoint Test E for coupe B1408 Power Window Driver Up Circuit Short to Battery GEM GO to Pinpoint Test D for convertible or Pinpoint Test E for coupe B1410 Power Window Driver Motor Circuit Failure GEM GO to Pinpoint Test D for convertible or Pinpoint Test E for coupe B1426 Lamp Safety Belt Circuit Short to...

Page 3717: ...Battery GEM GO to Section 501 14B B1555 Ignition RUN START Circuit Failure GEM GO to Section 211 05 B1603 Lamp Anti Theft Indicator Circuit Failure GEM GO to Section 419 01 B1605 Lamp Anti Theft Indicator Circuit Short to Battery GEM GO to Section 419 01 B1687 Lamp Dome Input Circuit Short to Battery GEM GO to Section 417 02 B1833 Door Unlock Disarm Switch Circuit Short to Ground GEM GO to Section...

Page 3718: ...erative driver convertible Circuitry CJB fuse 43 20A Ignition switch Window regulator motor Window regulator control switch GEM GO to Pinpoint Test D A single power window is inoperative driver coupe Circuitry CJB fuse 43 20A Ignition switch Window regulator motor Window regulator control switch GEM GO to Pinpoint Test E The one touch down feature is inoperative Circuitry CJB fuse 43 20A Ignition ...

Page 3719: ...apter s when making measurements Failure to use the correct probe adapter s may damage the connector A1 CHECK THE GENERIC ELECTRONIC MODULE GEM POWER SUPPLY Key in OFF position Disconnect Generic Electronic Module GEM C201a Disconnect GEM C201b Key in ON position Using the following table measure the voltage between the GEM harness side and ground Are the voltages greater than 10 volts Connector P...

Page 3720: ... for normal operation No REFER to Section 418 00 Test Step Result Action to Take B1 CHECK THE POWER SUPPLY TO THE WINDOW REGULATOR CONTROL SWITCH Key in OFF position Disconnect Driver Window Regulator Control Switch C537 Key in ON position Measure the voltage between driver window regulator control switch C537 pin 15 circuit 400 LB BK harness side and ground Is the voltage greater than 10 volts Ye...

Page 3721: ...tion Disconnect Driver Window Regulator Control Switch C508 Key in ON position Measure the voltage between driver window regulator control switch C508 pin 10 circuit 400 LB BK harness side and ground Is the voltage greater than 10 volts Yes GO to C2 No REPAIR the circuit TEST the system for normal operation C2 CHECK CIRCUIT 1205 BK FOR AN OPEN Measure the resistance between driver window regulator...

Page 3722: ...e diagnostic tool GEM PID D_UP_SW and D_DN_SW Actuate the driver window regulator control switch to the UP and DOWN position Did the PID values agree with the driver window regulator control switch positions Yes GO to D9 No GO to D3 D3 CHECK THE POWER SUPPLY TO THE WINDOW REGULATOR CONTROL SWITCH Disconnect Driver Window Regulator Control Switch C537 Key in ON position Measure the voltage between ...

Page 3723: ...ER to Switch Window Regulator Control in this section TEST the system for normal operation D6 CHECK CIRCUIT 226 WH BK FOR A SHORT TO BATTERY Key in OFF position Disconnect GEM C201a Measure the voltage between GEM C201a pin 2 circuit 226 WH BK harness side and ground Key in ON position Measure the voltage between GEM C201a pin 2 circuit 226 WH BK harness side and ground Is either voltage greater t...

Page 3724: ...ces less than 5 ohms Yes INSTALL a new GEM REFER to Section 419 10 TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation D8 CHECK CIRCUIT 400 LB BK FOR AN OPEN Key in OFF position Disconnect CJB Circuit Breaker 43 20A Measure the resistance between driver window regulator control switch C537 pin 15 circuit 400 LB BK harness side and CJB circuit breaker 43 ...

Page 3725: ...mentarily connect a jumper wire between second pin of the window regulator motor and ground Reverse the jumper wires on the window regulator motor Did the window regulator motor operate in both directions Yes GO to D11 No INSTALL a new window regulator motor REFER to Motor Window Regulator in this section TEST the system for normal operation D11 CHECK CIRCUIT 992 WH BK FOR AN OPEN BETWEEN THE DRIV...

Page 3726: ...3 CHECK CIRCUIT 400 LB BK FOR AN OPEN TO THE GEM Key in OFF position Disconnect CJB Circuit Breaker 43 20A Measure the resistance between GEM C021a pin 4 circuit 400 LB BK harness side and CJB circuit breaker 43 20A output pin circuit 400 LB BK Is the resistance less than 5 ohms Yes INSTALL a new GEM REFER to Section 419 10 TEST the system for normal operation No REPAIR the circuit TEST the system...

Page 3727: ...ey in ON position Measure the voltage between driver window regulator control switch C508 pin 10 circuit 400 LB BK harness side and ground Is the voltage greater than 10 volts Yes GO to E4 No GO to E8 E4 CHECK CIRCUIT 1205 BK FOR AN OPEN Measure the resistance between driver window regulator control switch C508 pin 7 circuit 1205 BK harness side and ground and between driver window regulator contr...

Page 3728: ... volts Yes REPAIR the circuit TEST the system for normal operation No GO to E7 E7 CHECK CIRCUIT 991 TN LB AND 992 WH BK FOR AN OPEN Key in OFF position Disconnect GEM C201c Measure the resistance between driver window regulator control switch C508 pin 6 circuit 991 TN LB harness side and GEM C201a pin 3 circuit 991 TN LB harness side Measure the resistance between driver window regulator control s...

Page 3729: ...e circuit TEST the system for normal operation E9 CHECK THE GEM CONTROL OF THE DRIVER POWER WINDOW Key in ON position Enter the following diagnostic mode on the diagnostic tool GEM Active Command FRONT WINDOW CONTROL Trigger DR DOWN ON Did the driver window move down Yes INSTALL a new GEM REFER to Section 419 10 TEST the system for normal operation No GO to E10 E10 CHECK THE WINDOW REGULATOR MOTOR...

Page 3730: ... side Is the resistance less than 5 ohms Yes GO to E12 No REPAIR the circuit TEST the system for normal operation E12 CHECK CIRCUIT 226 WH BK FOR AN OPEN Disconnect GEM C201a Measure the resistance between GEM C201a pin 2 circuit 226 WH BK harness side and driver window motor C518 circuit 226 WH BK harness side Is the resistance less than 5 ohms Yes GO to E13 No REPAIR the circuit TEST the system ...

Page 3731: ...Yes GO to F2 No GO to F15 F2 CHECK CIRCUIT 334 RD YE FOR GROUND Key in OFF position Disconnect Passenger Window Regulator Motor C623 Measure the resistance between passenger window regulator motor C623 circuit 334 RD YE harness side and ground Is the resistance less than 5 ohms Yes GO to F8 No GO to F3 F3 CHECK CIRCUIT 314 TN LB FOR GROUND Disconnect Passenger Window Regulator Control Switch C629 ...

Page 3732: ...the circuit TEST the system for normal operation F5 CHECK CIRCUIT 314 TN LB FOR AN OPEN COUPE Disconnect Driver Window Regulator Control Switch C508 Measure the resistance between driver window regulator control switch C508 pin 8 circuit 314 TN LB harness side and passenger window regulator control switch C629 pin 9 circuit 314 TN LB harness side Is the resistance less than 5 ohms Yes GO to F6 No ...

Page 3733: ...ndow regulator control switch TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation F8 CHECK CIRCUIT 333 YE RD FOR GROUND Measure the resistance between passenger window regulator motor C623 circuit 333 YE RD harness side and ground Is the resistance less than 5 ohms Yes GO to F14 No GO to F9 F9 CHECK CIRCUIT 313 WH YE FOR GROUND Disconnect Passenger Windo...

Page 3734: ... circuit TEST the system for normal operation F11 CHECK CIRCUIT 313 WH YE FOR AN OPEN COUPE Disconnect Driver Window Regulator Control Switch C508 Measure the resistance between driver window regulator control switch C508 pin 15 circuit 313 WH YE harness side and passenger window regulator control switch C629 pin 7 circuit 313 WH YE harness side Is the resistance less than 5 ohms Yes GO to F12 No ...

Page 3735: ...ver window regulator control switch component test REFER to Wiring Diagrams Cell 149 Component Testing Is the driver window regulator control switch OK Yes INSTALL a new passenger window regulator motor REFER to Motor Window Regulator in this section TEST the system for normal operation No INSTALL a new driver window regulator control switch REFER to Switch Window Regulator Control in this section...

Page 3736: ...8 circuit 194 PK harness side Is the resistance less than 5 ohms Yes INSTALL a new driver window regulator control switch REFER to Switch Window Regulator Control in this section TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation Test Step Result Action to Take G1 CHECK CIRCUIT 316 YE LB OR 319 YE BK FOR GROUND Disconnect Rear Window Regulator Motor C31...

Page 3737: ...e the resistance between left rear window regulator motor C3118 circuit 317 GY OG harness side and ground or between right rear window regulator motor C3119 circuit 320 RD BK harness side and ground Is the resistance less than 5 ohms Yes GO to G5 No GO to G4 G4 CHECK CIRCUIT 317 GY OG OR 320 RD BK FOR AN OPEN Disconnect Driver Window Regulator Control Switch C537 Measure the resistance between lef...

Page 3738: ...normal operation Test Step Result Action to Take H1 CHECK POWER TO INDICATOR LIGHT Key in ON position Depress the rear window defrost switch to ON Is the rear window defrost switch indicator ON Yes GO to H2 No GO to H3 H2 CHECK CIRCUIT 186 BR LB FOR AN OPEN Key in OFF position Disconnect Heated Rear Window Relay Disconnect Heated Rear Window Grid Power Supply Connector C402a Measure the resistance...

Page 3739: ...round Is the voltage greater than 10 volts Yes REPAIR the circuit CLEAR the DTCs REPEAT the self test No INSTALL a new rear window defrost switch REFER to Rear Window Defrost Switch in this section TEST the system for normal operation H6 CHECK THE REAR HEATED WINDOW GRID POWER Disconnect Heated Rear Window Grid Power Supply Connector C402a Key in ON position Depress the rear window defrost switch ...

Page 3740: ...e between heated rear window relay pin 85 circuit 727 YE BK harness side and ground Is the resistance less than 5 ohms Yes GO to H9 No GO to H11 H9 CHECK CIRCUIT 185 BK FOR POWER Measure the voltage between heated rear window relay pin 86 and pin 30 circuit 185 BK harness side and ground Are the voltages greater than 10 volts Yes GO to H10 No REPAIR the supply circuit TEST the system for normal op...

Page 3741: ...in OFF position Measure the resistance between ICM C220a pin 10 circuit 727 YE BK harness side and the heated rear window relay pin 85 circuit 727 YE BK harness side Is the resistance less than 5 ohms Yes GO to H16 No REPAIR the circuit TEST the system for normal operation H13 CHECK POWER TO REAR WINDOW DEFROST SWITCH Disconnect Rear Window Defrost Switch C241 Key in ON position Measure the voltag...

Page 3742: ...41 pin 2 circuit 175 BK YE harness side Is the resistance less than 5 ohms Yes INSTALL a new rear window defrost switch REFER to Rear Window Defrost Switch in this section TEST the system for normal operation No REPAIR the circuit TEST the system for normal operation H16 CHECK THE ICM FOR CORRECT OPERATION Disconnect all ICM connectors Check for corrosion pushed out pins Connect all ICM connectors...

Page 3743: ...I3 No GO to I2 I2 CHECK CIRCUIT 727 YE BK FOR A SHORT TO GROUND Key in OFF position Measure the resistance between instrument cluster module ICM C220a pin 10 circuit 727 YE BK harness side and ground Is the resistance greater than 10 000 ohms Yes GO to I4 No REPAIR the circuit TEST the system for normal operation I3 CHECK CIRCUIT 186 BN LB FOR A SHORT TO POWER Disconnect Heated Rear Window Grid Po...

Page 3744: ...h each grid line of the heated rear window glass at its midpoint with the positive lead A reading of approximately 6 volts indicates that the line is good A reading of zero volts indicates that the line is broken between the midpoint and the B side of the grid line A reading of 12 volts indicates that the circuit is broken between the midpoint of the grid line and ground Is the voltage greater tha...

Page 3745: ......

Page 3746: ... any inoperative grid wires using rear window defroster repair 2 Bring the vehicle up to room temperature of at least 16 C 60 F or above 3 Clean the entire grid line repair area with a non alcohol based window cleaner and 0000 steel wool 4 Mark the location of the grid break on the exterior of the rear window glass SECTION 501 11 Glass Frames and Mechanisms 2003 Mustang Workshop Manual Material It...

Page 3747: ...oth sides of the break area NOTE Allow at least five minutes of drying time between applications Apply the repair coating to the grid break area in several smooth continuous strokes Apply three applications of the grid repair compound 7 After five minutes or after the repair area has dried completely remove the mask 8 CAUTION Be careful not to damage the grid line with the razor blade If this occu...

Page 3748: ......

Page 3749: ...Allow 10 minutes of drying time between the coats Apply three coats of rear window defroster repair to the surface 3 CAUTION Do not overheat the rear window glass or damage to the rear window glass may occur SECTION 501 11 Glass Frames and Mechanisms 2003 Mustang Workshop Manual Special Tool s Heat Gun 107 R0300 or equivalent Material Item Specification Rear Window Defroster Repair D8AZ 19562 AA W...

Page 3750: ...g gun as soon as the solder flows Preheat the rear window glass in the area to be repaired using the special tool and solder the terminal to the bus bar 5 NOTE Turn the heated rear window switch ON for five minutes prior to the final inspection of the repair Apply rear window defroster repair to the area as needed ...

Page 3751: ......

Page 3752: ...ow Glass Adjustment Height Stop Adjustment 1 Close the front door 2 Loosen the screws 3 Raise the door window glass to the desired height 4 Tighten the screws SECTION 501 11 Glass Frames and Mechanisms 2003 Mustang Workshop Manual ...

Page 3753: ......

Page 3754: ...lizer 1 Raise the door window glass to the full up position 2 Loosen the bolts 3 Push the door window glass inner stabilizers firmly against the door window glass 4 Tighten the bolts SECTION 501 11 Glass Frames and Mechanisms 2003 Mustang Workshop Manual ...

Page 3755: ......

Page 3756: ...just the quarter window glass for correct fit 1 horizontal adjustment 2 regulator plate tilt 3 glass to regulator tilt 4 front high low up stop 5 rear high low tilt channel stop 6 inboard outboard tilt SECTION 501 11 Glass Frames and Mechanisms 2003 Mustang Workshop Manual ...

Page 3757: ...e door trim panel may occur Position the window regulator switch plate aside 1 Pull at the service notch 2 Lift to release the clip at the rear edge 2 Remove the window regulator control switch 1 Remove the screws 2 Disconnect the connectors Installation 1 To install reverse the removal procedure SECTION 501 11 Glass Frames and Mechanisms 2003 Mustang Workshop Manual ...

Page 3758: ......

Page 3759: ... 1 Remove the instrument panel center finish panel For additional information refer to Section 501 12 2 Release the clips and remove the rear window defrost switch 3 To install reverse the removal procedure SECTION 501 11 Glass Frames and Mechanisms 2003 Mustang Workshop Manual ...

Page 3760: ...ility knife 5 Using a soft brush or vacuum remove any dirt or foreign material from the pinch weld 6 CAUTION Care must be taken to prevent scratching the pinch weld NOTE Lubricate the existing urethane adhesive with water to aid the special tool while cutting Using the special tool starting at the top center of the back window glass cut the urethane adhesive from the glass and work down the sides ...

Page 3761: ...back window glass the vehicle should not be driven until the urethane adhesive has cured The curing time at temperatures above 13 C 55 F and relative humidity above 50 is 12 24 hours Refer to ESSEX drive away chart for cure times as temperatures and humidity vary Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive bond 2 Dry fit the back window gla...

Page 3762: ...installed attach the new moulding to the edge of the glass starting at the top center then work down the sides and around the corners If installing a new back window glass clean the inside of the glass surface with an alcohol free cleaner to make sure the ceramic coated area is clean 7 CAUTION Wipe off the urethane glass prep immediately after each application because it flash dries Apply delibera...

Page 3763: ... or Essex U 216 meeting Ford specification WSB M2G316 B to the pinch weld 11 CAUTION Open a window to prevent the back window glass from being pushed out by air pressure when the door is closed Using the alignment marks install the back window glass 12 After the glass is set check for water leaks and add urethane adhesive where needed 13 Install the headliner 14 Install the roof side trim moulding...

Page 3764: ... additional information refer to Section 501 05 2 Remove the interior weatherstrip 3 Remove the bolts and the stabilizers 4 Remove the bolts and the upstop brackets 5 Remove the rivet and the exterior weatherstrip SECTION 501 11 Glass Frames and Mechanisms 2003 Mustang Workshop Manual ...

Page 3765: ...6 Remove the rivets 7 Tip the front of the glass down to clear the door filler and remove the door window glass Installation 1 To install reverse the removal procedure ...

Page 3766: ...ion 501 05 2 Remove the roof side trim moulding For additional information refer to Section 501 08 3 Remove the exterior quarter glass weatherstrip 4 Remove the nuts 5 Remove the quarter window glass Installation 1 To install reverse the removal procedure SECTION 501 11 Glass Frames and Mechanisms 2003 Mustang Workshop Manual ...

Page 3767: ......

Page 3768: ...uarter trim panel For additional information refer to Section 501 05 2 Disconnect the connectors and remove the screw 3 Remove the screw 4 Remove the screw and the speaker 5 Disconnect the electrical connector SECTION 501 11 Glass Frames and Mechanisms 2003 Mustang Workshop Manual ...

Page 3769: ...6 Remove the watershield 7 Remove the interior weatherstrip 8 Remove the bolt 9 Remove the bolts and the glass ...

Page 3770: ...Installation 1 To install reverse the removal procedure ...

Page 3771: ...tional information refer to Section 501 05 2 Remove the screws and the speaker 3 Disconnect the electrical connector 4 Remove the screws and the window regulator motor Installation 1 To install reverse the removal procedure SECTION 501 11 Glass Frames and Mechanisms 2003 Mustang Workshop Manual ...

Page 3772: ......

Page 3773: ...he quarter trim panel For additional information refer to Section 501 05 2 Remove the watershield 3 Remove the quarter glass window regulator motor Installation 1 To install reverse the removal procedure SECTION 501 11 Glass Frames and Mechanisms 2003 Mustang Workshop Manual ...

Page 3774: ......

Page 3775: ...lass For additional information refer to Window Glass Door in this section 2 Disconnect the electrical connector 3 Remove the channel 4 Remove the regulator Installation 1 To install reverse the removal procedure SECTION 501 11 Glass Frames and Mechanisms 2003 Mustang Workshop Manual ...

Page 3776: ......

Page 3777: ...ow glass For additional information refer to Window Glass Quarter in this section 2 Remove the nut 3 Remove the screws and the rear quarter window regulator Installation 1 To install reverse the removal procedure SECTION 501 11 Glass Frames and Mechanisms 2003 Mustang Workshop Manual ...

Page 3778: ......

Page 3779: ...shield side garnish mouldings If equipped with a convertible top remove the pin type retainers 2 Remove the interior rear view mirror Convertible 3 Remove the visor trim moulding SECTION 501 11 Glass Frames and Mechanisms 2003 Mustang Workshop Manual Special Tool s Rotunda Pneumatic Knife with Offset Blade 107 R1511 or equivalent The Pumper 164 R2459 or equivalent Rotunda Interior Auto Glass Cut O...

Page 3780: ...emove the screws and the sun visors Disconnect the electrical connector s 5 Remove the weatherstrips 6 Remove the screws and the weatherstrip retainers 7 Remove the screw and the exterior A pillar moulding ...

Page 3781: ... moulding For additional information refer to Section 501 08 10 Lower the front portion of the headliner All vehicles 11 Remove the two windshield wiper pivot arms 1 Raise up on the pivot arms 2 Release the retainer tabs and release the windshield wiper pivot arms 12 Remove the cowl grille weatherstrip ...

Page 3782: ...age CAUTION Care must be taken to prevent scratching the pinch weld NOTE Lubricate the existing urethane adhesive with water to aid the special tool while cutting Using the special tool starting at the top center of the windshield cut the urethane adhesive from the windshield glass and work down the sides 16 Using the special tool distance the windshield glass from the body ...

Page 3783: ...e times as temperatures and humidity vary Inadequate curing of the urethane adhesive may adversely affect the strength of the urethane adhesive bond 1 Dry fit the windshield glass by centering it side to side and by adjusting the setting blocks if equipped to get the correct position of the part top to bottom Make alignment marks with tape or non staining grease pencil on both the glass and the ve...

Page 3784: ...kes making sure not to overlap the applied area If installing a new windshield glass apply Urethane Glass Prep Essex U 401 meeting Ford specification WSB M2G314 B twice around the class surface to be prepped 7 If installing a new windshield glass apply Urethane Glass Primer Essex U 402 meeting Ford specification WSB M5B280 C to the same area that was in the previous step Allow five minutes to dry ...

Page 3785: ...ll the windshield glass 11 After the glass is set check for water leaks and add urethane adhesive where needed 12 Install the cowl grille 13 Install the cowl grille weatherstrip 14 Install the two windshield wiper pivot arms Position the arms Install the windshield wiper pivot arms 15 Install the headliner Coupe 16 Install the sun visors and clips ...

Page 3786: ...ding For additional information refer to Section 501 08 Convertible 18 Install the exterior A pillar moulding and screw 19 Install the weatherstrip retainers 20 Install the weatherstrips 21 Position the sun visors and install the screws ...

Page 3787: ...connector s 22 Install the visor trim moulding All vehicles 23 Install the RH and LH windshield side garnish moulding If equipped with a convertible top install the pin type retainers 24 Install the interior rear view mirror ...

Page 3788: ......

Page 3789: ...itional information refer to Section 501 05 2 Remove the watershield 3 Position the door window glass in the full up position 4 Remove the nuts and the door glass run Installation 1 To install reverse the removal procedure SECTION 501 11 Glass Frames and Mechanisms 2003 Mustang Workshop Manual ...

Page 3790: ...s Description Nm lb ft lb in Bulkhead wiring harness electrical connector bolt 5 44 Floor console screws 2 18 Instrument panel support bolts 9 80 Instrument panel support nut 48 35 Intermediate shaft pinch bolt 47 35 Instrument panel reinforcement screws 9 80 Instrument panel steering column cover screws 9 80 ...

Page 3791: ...ent cluster instrument panel finish panels audio unit A C controls glove compartment door passenger air bag module glove compartment instrument panel steering column cover instrument panel reinforcement instrument panel defroster grille SECTION 501 12 Instrument Panel and Console 2003 Mustang Workshop Manual ...

Page 3792: ...nts console glove compartment console glove compartment door beverage holder cigar lighter knob and element power point glove compartment hinge console finish panel coin holder convertible top control switch if equipped SECTION 501 12 Instrument Panel and Console 2003 Mustang Workshop Manual ...

Page 3793: ...ve the LH front wheel and tire assembly For additional information refer to Section 204 04 4 Position the LH fender splash shield away from the dash panel 1 Remove the pin type retainers 2 Remove the screws 3 Position the LH fender splash shield away from the dash panel 5 Disconnect the bulkhead electrical connector from inside the fender opening 1 Loosen the bolt 2 Disconnect the bulkhead electri...

Page 3794: ...ion 204 04 8 Remove the floor console For additional information refer to Floor Console in this section 9 Remove the upper RH instrument panel support bolt 10 Disconnect the antenna in line connector 11 Disconnect the climate control vacuum harness connector 12 Close the glove compartment ...

Page 3795: ...the pin type retainers 2 Remove the A pillar lower trim panels 15 Remove the LH and RH windshield side garnish mouldings If equipped with a convertible top remove the pin type retainers 16 Position the LH and RH door weatherstrips aside 17 Disconnect the RH main wiring harness electrical connectors ...

Page 3796: ...steering column cover 1 Remove the screws 2 Remove the instrument panel steering column cover 20 Remove the instrument panel reinforcement 1 Remove the screws 2 Remove the instrument panel reinforcement 21 Separate the intermediate shaft from the steering column shaft 1 Remove the pinch bolt ...

Page 3797: ...ed back slightly to carry out this step Disconnect the LH main wiring harness electrical connectors 23 Disconnect the generic electronic module GEM electrical connectors 24 Disconnect the electronic crash sensor ECS module electrical connector 1 Release the locking tab 2 Disconnect the ECS module electrical connector ...

Page 3798: ... selector lever 26 Remove the audio unit For additional information refer to Section 415 01 27 If equipped disconnect the shifter assembly electrical connector 28 NOTE This step is being carried out through the audio unit opening NOTE Rotate the temperature control switch to the cool position Release the temperature control cable from the blend door 29 Remove the four center instrument panel suppo...

Page 3799: ...30 Remove the LH instrument panel support bolt and nut 31 Remove the RH instrument panel support bolt 32 Remove the instrument panel defroster grille 33 Remove upper instrument panel support bolts ...

Page 3800: ...les are sensitive to static electrical charges If exposed to these charges damage may result 1 NOTE Two technicians are necessary to carry out this step Install the instrument panel 2 Install the upper instrument panel support bolts 3 Install the instrument panel defroster grille 4 Install the RH instrument panel support bolt ...

Page 3801: ...d nut 6 Install the four center instrument panel support bolts 7 NOTE This step is being carried out through the audio unit opening Install the temperature control cable to the blend door 8 If equipped connect the shifter assembly electrical connector ...

Page 3802: ...erlock assembly to the selector lever 1 Position the shift interlock assembly 2 Connect the shift interlock cable 3 Install the R clip 4 Install the screw 11 Connect the ECS module electrical connector 1 Connect the ECS module electrical connector 2 Engage the locking tab 12 Connect the GEM electrical connectors ...

Page 3803: ...g column 1 Connect the intermediate shaft to the steering column 2 Install the pinch bolt 15 Install the instrument panel reinforcement 1 Position the instrument panel reinforcement 2 Install the screws 16 Install the instrument panel steering column cover 1 Position the instrument panel steering column cover ...

Page 3804: ...l wiring harness connector 18 Connect the RH main harness electrical connectors 19 Install the LH and RH door weatherstrips 20 Install the LH and RH windshield side garnish mouldings If equipped with a convertible top install the pin type retainers ...

Page 3805: ...ls 1 Position the LH and RH A pillar lower trim panels 2 Install the pin type retainers 22 Install the LH and RH scuff plates 23 Open the glove compartment 24 Connect the antenna in line connector 25 Install the upper RH instrument panel support bolt ...

Page 3806: ...wheel and tire assembly For additional information refer to Section 204 04 29 Insert the bulkhead electrical connector into the dash panel 30 Connect the bulkhead electrical connector 1 Connect the bulkhead electrical connector 2 Tighten the bolt 31 Install the LH front splash shield 1 Position the LH front splash shield 2 Install the screws 3 Install the pin type retainers ...

Page 3807: ...assembly For additional information refer to Section 204 04 33 Install the passenger air bag module For additional information refer to Section 501 20B 34 Install the driver air bag module For additional information refer to Section 501 20B ...

Page 3808: ...ansmission 2 Place the selector lever in the 1 position Vehicles with manual transmission 3 Remove the gearshift lever handle All vehicles 4 Remove the floor console finish panel Disconnect the electrical connector 5 Remove the instrument panel center finish panel Disconnect the electrical connector 6 To install reverse the removal procedure SECTION 501 12 Instrument Panel and Console 2003 Mustang...

Page 3809: ......

Page 3810: ...nsmission 3 Place the selector lever in the 1 position Vehicles with manual transmission 4 Remove the gearshift lever handle All vehicles 5 Remove the floor console finish panel Disconnect the electrical connector 6 Open the floor console glove compartment door 7 Remove the floor console screws 8 Disconnect the floor console electrical connector SECTION 501 12 Instrument Panel and Console 2003 Mus...

Page 3811: ...9 Remove the screws and the floor console 10 To install reverse the removal procedure ...

Page 3812: ...ft lb in Door latch screws 12 9 Luggage compartment lid screws 9 80 Exterior door handle nuts 9 80 Luggage compartment lid latch striker screws 12 9 Fuel tank filler door retaining screws 3 27 Door latch striker plate screws 25 18 LOCK REPAIR REPLACEMENT SPECIFICATIONS Part Number Lock Repair Package Name F85Z 11582 AA Ignition Cylinder F8ZZ 6321990 AA Door Lock XR32 6343262 BA Luggage Compartment...

Page 3813: ......

Page 3814: ...tch control cylinder rod 22134 door latch striker plate 22008 front door latch remote control cable 221A00 door lock cylinder 21990 window regulator switch plates 14524 adjunct actuator 218B20 circuit wiring and circuit protection front door lock switch 14017 luggage compartment lid latch with mechanical interior release handle and cable luggage compartment lid lock cylinder Refer to Section 501 1...

Page 3815: ......

Page 3816: ... Locks Latches And Mechanisms Refer to Section 501 14B for power door lock and luggage compartment lid remote control lock switch diagnostics SECTION 501 14A Handles Locks Latches and Mechanisms 2003 Mustang Workshop Manual ...

Page 3817: ...o Section 501 05 2 Release the actuating rods by opening the clips 3 Using a screwdriver release the lock cylinder actuating rod 4 Remove the door latch screws 5 Disconnect the door ajar switch and the actuator electrical connectors SECTION 501 14A Handles Locks Latches and Mechanisms 2003 Mustang Workshop Manual ...

Page 3818: ...6 Remove the water shield 7 Release the interior door handle actuating cable 8 Remove the door latch Installation 1 To install reverse the removal procedure ...

Page 3819: ......

Page 3820: ...erior release handle Disconnect the luggage compartment lid lock actuator 432A38 cable 2 Remove the luggage compartment lid latch 43200 1 Disconnect the electrical connector 2 Remove the three bolts Installation 1 To install reverse the removal procedure SECTION 501 14A Handles Locks Latches and Mechanisms 2003 Mustang Workshop Manual ...

Page 3821: ......

Page 3822: ...mation refer to Section 501 05 2 Release the exterior door handle actuating rod by opening the clip 3 Remove the exterior door handle nuts 4 Remove the exterior door handle Installation 1 To install reverse the removal procedure SECTION 501 14A Handles Locks Latches and Mechanisms 2003 Mustang Workshop Manual ...

Page 3823: ......

Page 3824: ...itional information refer to Section 501 05 2 Remove the rivet 3 Remove the cable clip 4 Release the cable housing from the interior handle 5 Release the actuating cable from the interior handle and remove the handle SECTION 501 14A Handles Locks Latches and Mechanisms 2003 Mustang Workshop Manual ...

Page 3825: ...Installation 1 To install reverse the removal procedure ...

Page 3826: ...h lock cylinder 11582 1 Insert the ignition key and turn to the RUN position 2 Using a 1 8 inch drift press the ignition switch lock cylinder release pin through the access hole while pulling out the ignition switch lock cylinder 3 To install reverse the removal procedure Verify ignition switch lock cylinder operation SECTION 501 14A Handles Locks Latches and Mechanisms 2003 Mustang Workshop Manua...

Page 3827: ......

Page 3828: ...plemental Restraint System SRS Deactivation and Reactivation in this section 3 WARNING To reduce the risk of serious personal injury read and follow all warnings cautions notes and instructions in the steering wheel removal and installation procedure Remove the steering wheel assembly For additional information refer to Wheel in this section 4 Twist off the cap from the ignition switch cylinder 5 ...

Page 3829: ...switch lock cylinder breaks loose Remove and discard the ignition switch lock cylinder and clean the drill shavings from the steering column 6 Remove the bearing retainer 7 Remove the bearing and gear Thoroughly clean all drill shavings from the steering column and inspect it for damage 8 To install reverse the removal procedure Install a new ignition switch lock cylinder Verify ignition switch lo...

Page 3830: ... read and follow all warnings cautions notes and instructions in the reactivation procedure Reactivate the supplemental restraint system SRS For additional information refer to Supplemental Restraint System SRS Deactivation and Reactivation in this section ...

Page 3831: ...on sheet to build the new lock cylinder to the current key code of the vehicle Remove the door trim panel 23942 For additional information refer to Section 501 05 2 Using a screwdriver release the lock cylinder actuating rod 3 Remove the door lock cylinder retainer 4 Remove the door lock cylinder 21990 5 If necessary transfer the lock cylinder arm to the new door lock cylinder 21990 SECTION 501 14...

Page 3832: ...Installation 1 To install reverse the removal procedure ...

Page 3833: ...package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle Disconnect the luggage compartment lid lock actuator 432A38 cable 2 Remove the luggage compartment lid lock cylinder 43262 1 Remove the rivet 2 Rotate the lock cylinder counterclockwise to remove Installation 1 To install reverse the removal procedure SECTION 501 14A Handles Locks La...

Page 3834: ......

Page 3835: ...the door trim panel 23942 For additional information refer to Section 501 05 2 Release the push button rod by opening the clip Installation 1 To install reverse the removal procedure SECTION 501 14A Handles Locks Latches and Mechanisms 2003 Mustang Workshop Manual ...

Page 3836: ...er to Section 501 05 2 Remove the door latch 21812 For additional information refer to Latch Door 3 Remove the door ajar switch Release the locking tab 4 Remove the adjunct actuator Installation 1 To install reverse the removal procedure SECTION 501 14A Handles Locks Latches and Mechanisms 2003 Mustang Workshop Manual ...

Page 3837: ......

Page 3838: ...l information refer to Section 501 05 2 Remove the door latch 21812 For additional information refer to Latch Door 3 Remove the door ajar switch Release the locking tab Installation 1 To install reverse the removal procedure SECTION 501 14A Handles Locks Latches and Mechanisms 2003 Mustang Workshop Manual ...

Page 3839: ...oid damaging the door trim panel Position the window regulator switch plate 14524 aside 1 Pull at service notch 2 Lift to release the clip at the rear edge 2 Remove the screws and the door lock switch 14017 Installation 1 To install reverse the removal procedure SECTION 501 14A Handles Locks Latches and Mechanisms 2003 Mustang Workshop Manual ...

Page 3840: ......

Page 3841: ...eyless Entry The electronic door lock system has two main components generic electronic module GEM 14B204 keyless entry remote transmitter 15K601 SECTION 501 14B Keyless Entry Computer Operated Locks 2003 Mustang Workshop Manual ...

Page 3842: ...lock all doors and lock all doors using a valid remote transmitter as long as the ignition switch is not in RUN or START The driver door is unlocked whenever the GEM detects a valid remote transmitter unlock transmission All the doors are unlocked when the GEM detects a second valid remote transmitter unlock transmission within three seconds of the first transmission All the doors are locked when ...

Page 3843: ...king lamps toggles the horn on and off The panic alarm is deactivated whenever GEM detects if the key causes a transition of the ignition switch circuits to ACC RUN START the remote transmitter panic button unlock button The panic alarm is also deactivated after 2 75 minutes have gone by Remote Transmitter Programming Operation This feature allows the customer to program up to four different trans...

Page 3844: ...d are related to the concern go to the GEM Diagnostic Trouble Code DTC Index to continue diagnostics 8 If no DTCs related to the concern are retrieved proceed to Symptom Chart to continue diagnostics GEM Diagnostic Trouble Code DTC Index Mechanical Electrical Binding latches CJB Fuses 39 5A 19 15A 25 25A BJB Fuse POWER WINDOWS 40A Damaged wiring harness Loose or corroded connector s Circuitry open...

Page 3845: ...point Test D B1603 Lamp Anti Theft Indicator Circuit Failure GEM REFER to Section 413 01 B1410 Driver Power Window Motor Circuit Failure GEM REFER to Section 501 11 B1426 Lamp Safety Belt Circuit Short to Battery GEM REFER to Section 413 01 B1428 Lamp Safety Belt Circuit Failure GEM REFER to Section 413 01 B1431 Wiper Brake Run Relay Circuit Failure GEM REFER to Section 501 16 B1432 Wiper Brake Ru...

Page 3846: ...t to Battery GEM REFER to Section 417 02 B2486 LF Side Repeater Lamp Output Circuit Failure GEM REFER to Section 417 01 B1605 Lamp Anti Theft Indicator Circuit Short to Battery GEM REFER to Section 501 16 B2488 RF Side Repeater Lamp Output Circuit Failure GEM REFER to Section 417 01 C1189 Brake Fluid Level Sensor Input Short Circuit to Ground GEM REFER to Section 413 01 C1223 Lamp Brake Warning Ou...

Page 3847: ...t Test E Test Step Result Action to Take CAUTION Use the correct probe adapter s when making measurements Failure to use the correct probe adapter s may damage the connector A1 CHECK THE GENERIC ELECTRONIC MODULE GEM POWER SUPPLY Key in OFF position Disconnect Generic Electronic Module GEM C201a Disconnect GEM C201b Key in ON position Using the following table measure the voltage between the GEM h...

Page 3848: ...ver and passenger power door lock and unlock switches Do the PID values agree with the switch positions Yes GO to B11 No GO to B2 B2 ISOLATE BETWEEN THE DRIVER AND PASSENGER POWER DOOR LOCK SWITCHES NOTE This PID may not be supported in the normal scan tool PID list It can be located in the Function test Transmitter Tic Data When this test is activated the appropriate results may be obtained when ...

Page 3849: ...h REPEAT the self test CLEAR the DTCs B5 CHECK CIRCUITS 129 LG AND 1014 VT FOR SHORT TO POWER Key in OFF position Disconnect GEM C201c Measure the voltage between GEM C201c Pin 20 Circuit 129 LG harness side and ground and between GEM C201c Pin 18 Circuit 1014 VT harness side and ground Key in ON position Measure the voltage between GEM C201c Pin 20 Circuit 129 LG harness side and ground and betwe...

Page 3850: ...tage between passenger window door lock control switch C629 Pin 3 Circuit 326 WH VT harness side and ground Is the voltage greater than 10 volts Yes GO to B8 No REPAIR Circuit 326 WH VT REPEAT the self test CLEAR the DTCs B8 CHECK THE PASSENGER POWER DOOR LOCK SWITCH FOR CORRECT OPERATION Carry out the passenger window door lock control switch component test REFER to Wiring Diagrams Cell 149 Compo...

Page 3851: ...between passenger window door lock control switch C629 Pin 4 Circuit 120 PK LG harness side and GEM C201c Pin 17 Circuit 120 PK LG harness side Are the resistances less than 5 ohms Yes INSTALL a new GEM For additional information REFER to Section 419 10 REPEAT the self test CLEAR the DTCs No REPAIR the circuit in question REPEAT the self test CLEAR the DTCs B11 CHECK GEM CONTROL OF THE POWER DOOR ...

Page 3852: ... component side Reverse the jumper wire connections and momentarily connect Did the driver door lock and unlock Yes GO to B14 No INSTALL a new driver door lock actuator For additional information REFER to Actuator REPEAT the self test CLEAR the DTCs B14 CHECK CIRCUIT 193 YE LG FOR OPEN NOTE Verify voltage at BJB Fuse POWER WINDOWS 40A before completing this step Disconnect GEM C201b Measure the vo...

Page 3853: ... resistances less than 5 ohms Yes INSTALL a new GEM For additional information REFER to Section 419 10 REPEAT the self test CLEAR the DTCs No REPAIR the circuit in question REPEAT the self test CLEAR the DTCs B17 CHECK THE PASSENGER POWER LOCK ACTUATOR OPERATION Disconnect Passenger Door Lock Actuator C603 Momentarily connect a fused 40A jumper wire between battery and passenger door lock actuator...

Page 3854: ...formation REFER to Section 419 10 REPEAT the self test CLEAR the DTCs No REPAIR the circuit in question REPEAT the self test CLEAR the DTCs Test Step Result Action to Take C1 CHECK THE LOCK OPERATION USING THE DRIVER DOOR LOCK SWITCH Lock and unlock the doors using the driver door lock switch Do all the doors lock and unlock correctly Yes GO to C2 No GO to Pinpoint Test B C2 CHECK IGNITION STATES ...

Page 3855: ...rying out the following procedure it must be noted that all previous programmed remote transmitters will be erased The customer needs to be informed that any remote transmitters not present during the programming mode will not operate the vehicle All remote transmitters must be programmed at the same time Reprogram the remote transmitter to the GEM For additional information refer to Programming K...

Page 3856: ...ming mode will not operate the vehicle All remote transmitters must be programmed at the same time Reprogram the remote transmitter to the GEM For additional information refer to Programming Keyless Entry Remote Transmitter Connect the diagnostic tool Monitor the GEM FUNCTION TEST TIC DATA while pressing the lock and unlock buttons on the remote transmitter Does LAST DATA RECEIVED match the button...

Page 3857: ...e luggage compartment lid release relay REFER to Wiring Diagrams Cell 149 Component Testing Is the luggage compartment lid release relay OK Yes GO to D9 No INSTALL a new luggage compartment lid release relay REPEAT the self test CLEAR the DTCs D9 CHECK CIRCUIT 599 PK LG FOR SHORT TO POWER Disconnect GEM C201c Measure the voltage between GEM C201c Pin 25 Circuit 599 PK LG harness side and ground Is...

Page 3858: ... Circuit 599 PK LG REPEAT the self test CLEAR the DTCs D12 CHECK CIRCUIT 84 VT YE FOR SHORT TO POWER Disconnect GEM C201c Measure the voltage between luggage compartment lid release relay Pin 3 Circuit 84 VT YE harness side and ground Is the voltage greater than 10 volts Yes REPAIR Circuit 84 VT YE REPEAT the self test CLEAR the DTCs No GO to D13 D13 CHECK CIRCUIT 84 VT YE FOR OPEN Disconnect Lugg...

Page 3859: ...while cycling the ignition switch through the OFF ACC RUN START and key out positions Do the PID values agree with the ignition switch positions Yes GO to E2 No REFER to Section 413 09 E2 CHECK THE GEM PID LAST DATA RECEIVED FOR PANIC Remove the ignition key from the ignition Connect the diagnostic tool Monitor the GEM PID LAST DATA RECEIVED while pressing and releasing the luggage compartment pan...

Page 3860: ...isconnect Horn Relay Disconnect GEM C201c Measure the voltage between GEM C201c Pin 12 Circuit 6 YE LG harness side and ground Is the voltage greater than 10 volts Yes GO to E7 No REPAIR Circuit 6 YE LG REPEAT the self test CLEAR the DTCs E7 CHECK CIRCUIT 6 YE LG FOR SHORT TO GROUND Measure the resistance between GEM C201c Pin 12 Circuit 6 YE LG harness side and ground Is the resistance greater th...

Page 3861: ...1e Measure the voltage between GEM C201e Pin 11 Circuit 1032 WH BK harness side and ground Is the voltage greater than 10 volts Yes GO to E11 No REPAIR Circuit 1032 WH BK REPEAT the self test CLEAR the DTCs E11 CHECK CIRCUIT 1032 WH BK FOR SHORT TO GROUND Measure the resistance between GEM C201e Pin 11 Circuit 1032 WH BK harness side and ground Is the resistance greater than 10 000 ohms Yes GO to ...

Page 3862: ...t 1032 WH BK REPEAT the self test CLEAR the DTCs E13 CHECK THE PARKING LAMPS FOR NORMAL OPERATION Turn the parking lamps on with the headlamp switch Did the parking lamps turn on and off with the headlamp switch Yes INSTALL a new GEM For additional information REFER to Section 419 10 REPEAT the self test CLEAR the DTCs No REFER to Section 417 01 ...

Page 3863: ... 7 5 seconds of entering the program mode and additional TICs must be entered within 7 5 seconds of the first TIC The programming mode is exited whenever the timing constraints are not met Press any button on a keyless entry remote transmitter and the doors will lock and then unlock to confirm that each keyless entry remote transmitter has been programmed 3 If the door locks do not respond for any...

Page 3864: ...REMOVAL AND INSTALLATION Actuator Removal and Installation For additional information refer to Section 501 14A SECTION 501 14B Keyless Entry Computer Operated Locks 2003 Mustang Workshop Manual ...

Page 3865: ...L AND INSTALLATION Module Generic Electronic GEM Removal and Installation For additional information refer to Section 419 10 SECTION 501 14B Keyless Entry Computer Operated Locks 2003 Mustang Workshop Manual ...

Page 3866: ...p edge of cowl top vent panel 55 88mm 2 16 3 18 inches LH wiper blade to top edge of cowl top vent panel 56 80mm 2 20 3 14 inches Torque Specifications Description Nm lb ft lb in Windshield wiper mounting arm and pivot shaft bolt 15 11 Windshield wiper motor bolts 15 11 Windshield washer fluid reservoir screw 6 53 Battery Ground Cable 10 89 ...

Page 3867: ...ts windshield wiper mounting arm and pivot shaft pivot arms windshield wiper blades windshield washer reservoir windshield washer pump windshield wiper motor generic electronic module GEM multi function switch windshield washer nozzle and bracket SECTION 501 16 Wipers and Washers 2003 Mustang Workshop Manual ...

Page 3868: ...GEM detects a high or low speed request from the wiper mode circuits the GEM will activate the wiper ON and OFF and the wiper speed circuits accordingly Wiper Motor Speeds Interval There are one to seven wiper speed intervals ranging from 1 5 seconds to 20 seconds in delay time respectively which can be selected When the GEM detects the ignition switch circuits are in the RUN or ACC states and the...

Page 3869: ...washer fluid from the front windshield Inspection and Verification 1 Verify the customer concern by operating the wiper washer system 2 Visually inspect for obvious signs of mechanical and electrical damage 3 If the concern remains after the inspection connect the diagnostic tool to the data link connector DLC located beneath the instrument panel and select the vehicle to be tested from the diagno...

Page 3870: ...1339 Chime Input Request Circuit Short to Battery FOJ GEM REFER to Section 413 09 B1340 Chime Input Request Circuit Short to Ground GEM REFER to Section 413 09 B1342 ECU Is Defective GEM CLEAR the DTCs Retrieve the DTCs If DTC B1342 is retrieved INSTALL a new GEM REFER to Section 419 10 B1353 Ignition Key In Circuit Open GEM REFER to Section 413 09 B1359 Ignition Run Acc Circuit Failure GEM REFER ...

Page 3871: ...o Pinpoint Test C B1462 Safety Belt Switch Circuit Failure GEM REFER to Section 413 09 B1466 Wiper HIGH and LOW Speed Not Switching GEM GO to Pinpoint Test B B1473 Wiper Low Speed Circuit Motor Failure GEM GO to Pinpoint Test B B1476 Wiper High Speed Circuit Motor Failure GEM GO to Pinpoint Test B B1551 Decklid Release Circuit Failure GEM REFER to Section 501 14B B1553 Decklid Release Circuit Shor...

Page 3872: ...HIGH LOW relay Wiper motor GO to Pinpoint Test B The HIGH and LOW wiper speeds do not operate correctly Circuitry GEM Multifunction switch Wiper HIGH LOW relay Wiper motor DTC B1434 GO to Pinpoint Test B The intermittent wiper mode does not operate correctly Circuitry GEM Multifunction switch Wiper motor GO to Pinpoint Test B The washer pump is inoperative CJB Fuse 26 30A Circuitry GEM Multifuncti...

Page 3873: ...t related to the symptom before installing a new GEM PINPOINT TEST A NO COMMUNICATION WITH THE GENERIC ELECTRONIC MODULE GEM Test Step Result Action to Take CAUTION Use the correct probe adapter s when making measurements Failure to use the correct probe adapter s may damage the connector A1 CHECK THE GENERIC ELECTRONIC MODULE GEM POWER SUPPLY Key in OFF position Disconnect Generic Electronic Modu...

Page 3874: ...ipped with a manual transmission depress the clutch while turning the ignition switch to START Monitor the GEM PIDs IGN_S IGN_R IGN_A and IGN_KEY while turning the ignition switch through the START RUN OFF and ACC positions Do the GEM PID values agree with the ignition switch positions Yes GO to B2 No REFER to Section 413 09 B2 DETERMINE IF GEM IS RECEIVING CORRECT WIPER SWITCH STATUS FROM MULTIFU...

Page 3875: ...6 TEST THE MULTIFUNCTION SWITCH FOR NORMAL OPERATION Disconnect Multifunction Switch C202a Check the multifunction switch Refer to Wiring Diagrams Cell 149 Component Testing Is the multifunction switch OK Yes GO to B7 No INSTALL a new multifunction switch REFER to Section 211 05 REPEAT the self test CLEAR the DTCs B7 CHECK CIRCUITS 682 DB 684 PK YE AND 680 LB OG FOR SHORT TO BATTERY BETWEEN THE GE...

Page 3876: ...able measure the resistance between the GEM C201e Pins harness side and multifunction switch C202a Pins harness side Are the resistances less than 5 ohms GEM Multifunction Switch Circuit C260 Pin 5 C202a Pin 685 682 DB C260 Pin 18 C202a Pin 590 684 PK YE C260 Pin 19 C202a Pin 993 680 LB OG Yes INSTALL a new GEM For additional information REFER to Section 419 10 REPEAT the self test CLEAR the DTCs ...

Page 3877: ...ion Did the wiper motor activate Yes GO to B12 No GO to B22 B12 CARRY OUT THE WIPER ON OFF RELAY COMPONENT TEST Check the wiper ON and OFF relay refer to Wiring Diagrams Cell 149 Component Testing Is the ON OFF wiper relay OK Yes GO to B13 No INSTALL a new wiper ON OFF relay REPEAT the self test CLEAR the DTCs B13 CHECK CIRCUIT 646 YE WH FOR SHORT TO BATTERY BETWEEN GEM AND BJB Disconnect Wiper On...

Page 3878: ...n 5 ohms Yes INSTALL a new GEM For additional information REFER to Section 419 10 REPEAT the self test CLEAR the DTCs No REPAIR Circuit 646 YE WH REPEAT the self test CLEAR the DTCs B16 CHECK CIRCUITS 65 DG AND 61 YE RD FOR OPEN CONDITION BETWEEN BJB AND CJB Disconnect Wiper HIGH LOW Relay Trigger the GEM active command WIPER RLY to ON Measure the voltages between BJB wiper HIGH LOW relay Pin 86 C...

Page 3879: ...relay OK Yes GO to B19 No INSTALL a new wiper HIGH LOW relay REPEAT the self test CLEAR the DTCs B19 CHECK CIRCUIT 647 GY LB FOR SHORT TO BATTERY BETWEEN GEM AND BJB Disconnect GEM C201d Measure voltage between GEM C201d Pin 5 Circuit 647 GY LB harness side and ground Is the voltage greater than 10 volts Yes REPAIR Circuit 647 GY LB REPEAT the self test CLEAR the DTCs No GO to B20 B20 CHECK CIRCUI...

Page 3880: ... 61 YE RD FOR OPEN CIRCUIT CONDITION BETWEEN WIPER ON OFF AND HIGH LOW RELAYS Disconnect Wiper HIGH LOW Relay Disconnect Wiper ON OFF Relay Measure the resistance between wiper ON OFF relay Pin 3 Circuit 61 YE RD harness side and wiper HIGH LOW relay Pin 30 Circuit 61 YE RD harness side Is the resistance less than 5 ohms Yes GO to B23 No REPAIR Circuit 61 YE RD REPEAT the self test CLEAR the DTCs ...

Page 3881: ...FER to Component Test If the component fails INSTALL a new wiper motor REFER to Motor Windshield Wiper REPEAT the self test CLEAR the DTCs No REPAIR Circuit 1205 BK REPEAT the self test CLEAR the DTCs B26 CHECK CIRCUIT 58 WH FOR AN OPEN CIRCUIT BETWEEN THE WIPER HIGH LOW RELAY AND THE WIPER MOTOR Disconnect Wiper Motor C125 Measure the resistance between wiper motor C125 Pin 5 Circuit 58 WH harnes...

Page 3882: ...switch to START Monitor the GEM PIDs IGN_S IGN_R IGN_A and IGN_KEY while turning the ignition switch through the START RUN OFF and ACC positions Do the GEM PID values agree with the ignition switch positions Yes GO to C2 No REFER to Section 413 09 C2 DETERMINE IF GEM IS RECEIVING CORRECT WIPER SWITCH STATUS FROM MULTIFUNCTION SWITCH Key in ON position Monitor GEM PID WPMODE while activating all wi...

Page 3883: ...3 Circuit 65 DG harness side and Pin 5 Circuit 941 BK WH harness side Did the washer motor activate Yes GO to C6 No GO to C10 C6 CARRY OUT WASHER ON OFF RELAY COMPONENT TEST Check the washer ON OFF relay refer to Wiring Diagrams Cell 149 Component Testing Is the washer ON OFF relay OK Yes GO to C7 No INSTALL a new wiper ON OFF relay REPEAT the self test CLEAR the DTCs C7 CHECK CIRCUIT 686 TN RD FO...

Page 3884: ... Is the resistance less than 5 ohms Yes INSTALL a new GEM REFER to Section 419 10 REPEAT the self test CLEAR the DTCs No REPAIR Circuit 686 TN RD REPEAT the self test CLEAR the DTCs C10 CHECK CIRCUIT 941 BK WH FOR SHORT TO BATTERY BETWEEN BJB AND WASHER MOTOR Disconnect Washer Pump Motor C137 Measure the voltage between washer pump C137 Pin 1 Circuit 941 BK WH harness side and ground Is the voltag...

Page 3885: ...e motor magnets Use Alternator Regulator Battery and Starter Tester ARBST to test the wiper motor on the vehicle Is the resistance less than 5 ohms REPAIR Circuit 941 BK WH REPEAT the self test CLEAR the DTCs C12 CHECK CIRCUIT 1205 BK FOR AN OPEN Measure the resistance between washer pump C137 Pin 2 Circuit 1205 BK harness side and ground Is the resistance less than 5 ohms Yes INSTALL a new washer...

Page 3886: ...n brush terminal terminal 3 Test the low speed mode by connecting a 5 cable from the battery positive post to the 6 low speed brush terminal terminal 4 and measure the current draw If the current draw is greater than 3 5 amperes install a new windshield wiper motor Test the high speed mode by connecting a cable from the battery positive post to the 7 high speed brush terminal terminal 5 and measur...

Page 3887: ......

Page 3888: ...cation 3 Verify that the distance between the center of the LH windshield wiper blade and the top edge of the cowl top vent panel is within specification 4 If the distance is not within specification remove the windshield wiper pivot arms and reposition to specification Remove the pivot arm 1 Pull up on the pivot arm 2 Pull out on the retainer tab and remove the pivot arm SECTION 501 16 Wipers and...

Page 3889: ......

Page 3890: ...r pivot arms need to be installed as an assembly Remove the pivot arm 1 Pull up on the pivot arm 2 Pull out on the retainer tab and remove the pivot arm Installation 1 To install reverse the removal procedure SECTION 501 16 Wipers and Washers 2003 Mustang Workshop Manual ...

Page 3891: ... 4 Disconnect the mounting arm and pivot shaft linkage from the wiper motor output shaft 1 Remove the clip 2 Disconnect the mounting arm and pivot shaft linkage from the wiper motor output shaft 5 NOTE It is necessary to lower the hood to remove the mounting arm and pivot shaft Remove the mounting arm and pivot shaft 1 Remove the bolts 2 Remove the mounting arm and pivot shaft through the RH cowl ...

Page 3892: ...arm and pivot shaft linkage onto the wiper motor output shaft Install the mounting arm and pivot shaft linkage onto the wiper motor output shaft Snap the mounting arm and pivot shaft linkage onto the wiper motor output shaft 3 NOTE When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driv...

Page 3893: ...5 Install the cowl top vent panels Adjust wiper pivot arms as necessary Refer to Wiper Blade and Pivot Arm Adjustment ...

Page 3894: ... new wiper motor 1 Park the windshield wipers in the full upright position This will allow for easy access to the retaining clip on the wiper motor output shaft 2 Remove the cowl top vent panels 3 Disconnect the negative battery cable 4 Disconnect the mounting arm and pivot shaft linkage from the wiper motor output shaft 1 Remove the clip 2 Disconnect the mounting arm and pivot shaft linkage 5 Rem...

Page 3895: ...inkage onto the wiper motor output shaft 3 NOTE When the battery is disconnected and reconnected some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven 16 km 10 miles or more to relearn the strategy Reconnect the negative battery cable 4 Cycle the wiper motor to the park position 5 Install the cowl top vent panels Adjust pivot arms...

Page 3896: ......

Page 3897: ...he windshield washer reservoir before removal Remove the washer pump 1 Disconnect the electrical connector 2 Disconnect washer hose from the washer pump 3 Remove the washer pump Installation 1 WARNING Windshield washer solution contains methanol which is poisonous Observe all cautions and warnings indicated on label of washer solution container CAUTION Do not operate the windshield washer pump pri...

Page 3898: ......

Page 3899: ...illing windshield washer fluid drain the windshield washer reservoir before removal Position windshield washer reservoir aside 1 Disconnect the electrical connector 2 Remove the bolt 3 Position windshield washer reservoir aside 4 Remove the washer fluid reservoir Disconnect the windshield washer pump hose Installation 1 WARNING Windshield washer solution contains methanol which is poisonous Observ...

Page 3900: ...CAUTION Do not operate the windshield washer pump prior to filling the windshield reservoir To install reverse the removal procedure Fill the windshield washer reservoir ...

Page 3901: ...REMOVAL AND INSTALLATION Module Generic Electronic GEM For additional information refer to Section 419 10 SECTION 501 16 Wipers and Washers 2003 Mustang Workshop Manual ...

Page 3902: ...REMOVAL AND INSTALLATION Switch Multi Function Removal and Installation For additional information refer to Section 211 05 SECTION 501 16 Wipers and Washers 2003 Mustang Workshop Manual ...

Page 3903: ...ting nut 23 17 Rail seal screws 3 27 Side rail bolts 63 46 Cylinder upper mounting bolt 17 13 Cylinder retaining bolts 22 16 Front safety belt retractor bolts and nut 30 20 Front seal screws 5 44 Cylinder rod mounting bolts 12 9 Side rail to header bolts 23 17 Tacking strip nuts 7 62 Hydraulic line to lift cylinder nuts 9 80 Hydraulic line to motor nuts 12 9 B Hinge lock nut 4 35 Balance linkage b...

Page 3904: ......

Page 3905: ...is attached to the bows and is repaired as a component Hydraulic System The convertible top hydraulic system is comprised of the lift cylinders the motor the connecting hydraulic lines and a convertible top switch The hydraulic system except for the convertible top switch is removed as an assembly but the components may be repaired separately SECTION 501 18 Convertible Top 2003 Mustang Workshop Ma...

Page 3906: ......

Page 3907: ...und Convertible Top Adjustments The convertible top adjustments must be made by a qualified technician Inspection and Verification 1 Verify the customer concern by operating the system 2 Visually inspect for obvious signs of mechanical or electrical damage 3 If an obvious cause for an observed or reported concern is found correct the cause if possible before proceeding to the next step 4 If the co...

Page 3908: ...system Convertible top adjustment Hydraulic lift cylinders Hydraulic motor pump assembly Hydraulic system Go To Pinpoint Test D Test Step Result Action to Take A1 CHECK THE CONVERTIBLE TOP OPERATION NOTE The parking brake must be applied for the convertible top system to operate Key in ON position Depress the convertible top switch in RAISE and LOWER positions while listening for motor operation D...

Page 3909: ...HECK CIRCUIT 688 GY LB FOR VOLTAGE Key in OFF position Disconnect Lower Relay C4064 Key in ON position Depress and hold the convertible top switch in the LOWER position Measure the voltage between lower relay C4064 pin 85 circuit 688 GY LB harness side and ground Is the voltage greater than 10 volts Yes GO to A9 No GO to A8 A5 CHECK CIRCUIT 588 VT FOR OPEN Key in OFF position Disconnect Convertibl...

Page 3910: ...n this section TEST the system for normal operation No REPAIR circuit 688 GY LB TEST the system for normal operation A7 CHECK THE BATTERY SUPPLY TO THE RELAYS Measure the voltage between raise relay C4063 pin 87 circuit 170 RD LB harness side and ground and between lower relay C4064 pin 87 circuit 170 RD LB harness side and ground Are the voltages greater than 10 volts Yes GO to A8 No REPAIR circu...

Page 3911: ...ness side and parking brake switch C306 circuit 22 LB BK harness side and between lower relay C4064 pin 86 circuit 977 VT WH harness side and parking brake switch C306 circuit 22 LB BK harness side Are the resistances less than 5 ohms Yes INSTALL a new parking brake switch REFER to Section 206 05 TEST the system for normal operation No REPAIR the circuit in question TEST the system for normal oper...

Page 3912: ...t TEST the system for normal operation A13 CHECK THE LOWER INPUT TO THE MOTOR Key in ON position Measure the voltage between convertible top motor C4062 circuit 902 YE harness side and ground Depress and hold the convertible top switch in the LOWER position Is the voltage greater than 10 volts Yes GO to A14 No INSTALL a new lower relay TEST the system for normal operation A14 CHECK THE CONVERTIBLE...

Page 3913: ... TEST the system for normal operation A16 CHECK THE RAISE INPUT TO THE MOTOR Key in ON position Depress and hold the convertible top switch in the RAISE position Measure the voltage between convertible top motor C4062 circuit 903 RD harness side and ground 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 ...

Page 3914: ...kage 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 Key in ON position Actuate the convertible top switch to the RAISE position Did the motor ope...

Page 3915: ...e 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 Bleed the hydraulic system Refer to System Bleeding in this section Does the system operate correctly after bleeding Yes CHECK all fittings and hoses for leaks REPAI...

Page 3916: ......

Page 3917: ...le 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 Au...

Page 3918: ...6 Install a fill plug 7 Install the hydraulic system in the vehicle Refer to Hydraulic System Lift Cylinder and Motor in this section ...

Page 3919: ...1 Remove the quarter trim panel For additional information refer to Section 501 05 2 Close the convertible top and examine the position of the dowel pins relative to the receiver cups 3 Move the convertible top to the half open position to access the cam bolt 4 NOTE Rotating the top of the cam bolt toward the front of the vehicle will lengthen the top increase the tension on the top and increase p...

Page 3920: ...rtible 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...

Page 3921: ...onvertible top to the half open position and support the convertible top in that position 13 Remove the lift cylinder rod mounting bolts 14 Remove the nuts and support the lift cylinders 15 Using the convertible top switch retract the lift cylinder rods and check for bent or binding rods ...

Page 3922: ... 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 scre...

Page 3923: ...st be adjusted to keep the door window glass from striking the convertible top preventing the door from closing 26 Remove the quarter trim panel For additional information refer to Section 501 05 NOTE Lowering the balance link will raise the No 1 bow position to the vehicle header and increase the pull down effort Raising the balance link will lower the No 1 bow to the header of the vehicle and de...

Page 3924: ...n refer to Section 501 05 NOTE If the B hinge set screw is adjusted to raise or lower the B hinge inspect the header height top pull down and dowl and receiver clearance Adjust the cam bolt and balance link as necessary 33 Tighten the lock nut Use Threadlock and sealer on the lock nut 34 Tighten the lock nut Threadlock and sealer on the lock nut 35 Make sure the convertible top operate correctly 3...

Page 3925: ......

Page 3926: ...el For additional information refer to Section 501 05 2 If necessary remove the bolts 3 Remove the nut and bolts and position the front safety belt retractor aside 4 Remove the two cylinder rod mounting bolts 5 Remove the cylinder rod mounting nut SECTION 501 18 Convertible Top 2003 Mustang Workshop Manual ...

Page 3927: ...6 Remove the screw and disconnect the two electrical connectors 7 Remove the screw 8 Remove the speaker 9 Remove the screws and the front seal 10 Remove the rail seals ...

Page 3928: ...11 Remove the rail seal retainers 12 Remove the headliner pin type retainers 13 Remove the headliner screws 14 Remove the speed nut ...

Page 3929: ...he front of the side rail and the header Record the figure and the position of the folding top 16 Separate the vinyl top cover flap from the rear rail 17 Disconnect the side tension cable from the rear rail 18 Remove the two bolts ...

Page 3930: ...latch the folding top after re positioning Position the folding top in the full up position 21 Disconnect the number two and number three bows from the side rail assembly 22 NOTE Mark the centerline locations for the number four bow screws Remove the screws ...

Page 3931: ... bottom bolt 2 Remove the upper bolt 24 Remove the side rail 1 Remove the two bolts 2 Loosen the bolt Installation 1 Position the side rail and install the bolts 2 NOTE Tighten the bottom bolt first Connect the mounting bracket and install the bolts ...

Page 3932: ...3 NOTE Line up the marks in the number four bow Tighten the bolt 4 Connect the number two and number three bows to the side rail assembly 5 Tighten the bolt 6 Hand tighten the two bolts ...

Page 3933: ...st the gap between the front of the side rail and the header to the previously recorded dimensions 8 Tighten the bolts 9 Connect the cable to the rear rail 10 Attach the vinyl top cover flap to the rear rail ...

Page 3934: ...11 Install the speed nut 12 Install the headliner screws 13 Attach the headliner pin type retainers 14 Install the rail seal screws ...

Page 3935: ...15 Install the rail seals 16 Install the screws and the front seal 17 Install the speaker 18 Install the screw 19 Install the screw and connect the electrical connectors ...

Page 3936: ...20 Position the cylinders and install the nuts 21 Install the two cylinder rod mounting bolts 22 Install the front safety belt retractor 23 Install the bolts ...

Page 3937: ...24 Install the side quarter trim panel For additional information refer to Section 501 05 ...

Page 3938: ...necessary 2 Remove the nuts retaining the well sling and convertible top tacking strips 3 Remove the three tacking strips 4 Mark the top of the convertible top skin around the top of all three tacking strips with a grease pencil 5 Remove the visible staples SECTION 501 18 Convertible Top 2003 Mustang Workshop Manual ...

Page 3939: ... bottom and the forward edge of the rear tacking strip 8 Remove the winter seal 9 Lift the rear cover assembly over the convertible top exposing the top of the rear window glass assembly 10 Remove all of the staples in the cover assembly along the number four bow ...

Page 3940: ...erlay the new rear window glass assembly over the old rear window glass assembly and transpose the markings with a grease pencil 2 Center the V notch on the new rear window glass assembly to the center mark on the top of the number four bow 3 Align the rear window glass assembly to the top groove of the number four bow and staple the entire length ...

Page 3941: ...e top edge of the rear belt to the reference line and staple 5 Repeat the procedure for both rear tacking strip sides 6 Position and staple the water diverter 7 If necessary align the elastic straps with the edge of the rear window glass assembly and staple in place ...

Page 3942: ...ear window glass assembly and staple the entire length 9 Align the top edge of the quarter tacking strip to the reference line on the convertible top cover and staple 10 Install the tacking strips over the body studs 11 Tighten the tacking strip nuts 12 Install the well sling ...

Page 3943: ...13 If necessary connect the rear defroster connectors ...

Page 3944: ...emoval 1 Remove the rear exterior trim mouldings 2 Remove the clips 3 Remove the 13 Torx screws and the seal compression panel 4 Remove the staples 5 Remove the staples from the number one bow SECTION 501 18 Convertible Top 2003 Mustang Workshop Manual ...

Page 3945: ...herstrip retainers from each side 7 Raise the front of the folding top assembly 8 Remove the screw and the center elastic straps 9 Remove the speed nut and the front elastic straps 10 Remove the screw and the front elastic strap ...

Page 3946: ...raps 12 Remove the screw and the rear elastic straps 13 NOTE Install new plastic roof headlining retaining pins if they were removed Disengage the roof headlining from the folding roof rear side rail 14 Remove the screws from the number four bow ...

Page 3947: ... from the number three bow 16 Remove the screws from the number two bow 17 Remove the headlining 18 Remove the nuts retaining the well sling and convertible top tacking strips 19 Remove screws and the three tacking strips ...

Page 3948: ...pe must be removed from the folding roof rear side rail Pull the roof outside cover flaps to disengage from each folding roof rear side rail 22 Remove the staples from the entire length of the number four bow 23 Disengage the cable from each side ...

Page 3949: ...ed Use care not to lose the cable end during disassembly Disconnect the trim tension cable 26 Remove the cover from the frame Installation 1 Align the center mark on the cover assembly to the V notch on the rear glass assembly and staple the entire length of the number four bow ...

Page 3950: ...ing top number two bow 3 Position the listing sleeve onto the number two bow with the headliner retainer 4 Install the screws for the number two bow 5 Pull the roof headlining over the top of the folding top header number one bow and staple the underside ...

Page 3951: ...d nut 7 Pull the folding top tension cable through the retainer in the roof outside cover 8 Engage the cable to the spring retainer 9 Staple the flap at the front of the roof outside cover to the tacking strip on the underside of the folding top header panel ...

Page 3952: ...the tacking strip 11 Fold the tab under the folding top header number one bow and clamp 12 Staple the rear of the roof outside cover to the side tacking strip 13 NOTE Make sure there are no wrinkles in the roof outside cover Install the remaining staples along the rear of the roof outside cover ...

Page 3953: ...r to the number three and four bow and install the screws 16 NOTE Make sure there are no wrinkles on the top of the roof outside cover Support the top and staple the underside of the folding top header panel from the center to the sides 17 Install the screws through the headlining and the strap into the front side rail ...

Page 3954: ...9 Position the rear elastic strap and install the screw 20 Position the rear elastic strap and install the screw 21 Trim the excess roof outside cover along the rear tacking strips and around the tacking strip mounting holes 22 NOTE Install new plastic roof headlining retaining pins if they were removed ...

Page 3955: ...oof headlining into the folding roof rear side rail 23 Install the seal compression panel 24 Install two sided tape on the rear rail 25 Install the flap onto the rear rail 26 Install the rear weatherstrip retainers ...

Page 3956: ...27 Install the clips 28 Install the exterior mouldings ...

Page 3957: ... Rear Window Glass in this section 3 NOTE Mark the old stay pad staple locations and transfer to the new stay pads Remove the staples from all of the bows Installation 1 Staple the stay pad to the number one bow 2 NOTE The stay pad should be tight between the number one and number four bows Staple the stay pad to the number four bow 3 Cut the excess stay pad material from the rear of the number fo...

Page 3958: ... to the number three bow 6 Install the rear window glass For additional information refer to Convertible Top Assembly Rear Window Glass in this section 7 Install the convertible top material For additional information refer to Convertible Top Material in this section ...

Page 3959: ......

Page 3960: ...1 Remove the floor console For additional information refer to Section 501 12 2 Remove the convertible top switch 1 Disconnect the electrical connector 2 Release the clips 3 To install reverse the removal procedure SECTION 501 18 Convertible Top 2003 Mustang Workshop Manual ...

Page 3961: ...re 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...

Page 3962: ...r the lift cylinders 8 Remove the nuts and the lift cylinders 9 Release the hydraulic line retainers on each side 10 Disconnect the motor electrical connector 11 Pull up on the motor to release the rubber retainers ...

Page 3963: ...n the new cylinder Remove the hydraulic lines from the cylinder Motor assembly 14 NOTE Prior to removal mark the hydraulic lines to insure correct installation of the motor assembly Remove the hydraulic lines from the motor assembly Installation Lift cylinder 1 NOTE Be sure that each fitting is installed in the correct position on the folding top hydraulic component ...

Page 3964: ...der 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 Con...

Page 3965: ...7 Engage the hydraulic line retainers on each side 8 Position the lift cylinders and install the nuts 9 Install the two cylinder rod mounting bolts 10 Install the speakers 11 Install the screws ...

Page 3966: ...es 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 ...

Page 3967: ...scription Nm lb ft lb in Front bumper bolts 40 30 Rear bumper bolts 23 17 Front bumper cover nuts 5 44 Rear bumper cover nuts 7 62 Exhaust outlet pipe bumper bracket bolts 18 13 Rear bumper tongue to frame rail bolts 63 46 Rear bumper brace bolts 48 35 Intercooler radiator bracket bolts 20 15 ...

Page 3968: ...se distortion of the bumper cover The bumper systems consist of the following components front bumper front bumper cover front bumper cover Cobra front bumper isolator rear bumper rear bumper brace rear bumper cover rear bumper cover Cobra rear bumper isolator SECTION 501 19 Bumpers 2003 Mustang Workshop Manual ...

Page 3969: ...nd Cobra similar 1 Remove the pin type retainers and the radiator upper sight shield 2 Remove the two pin type retainers one each side 3 Remove the four front bumper cover nuts two each side 4 Remove the lower bumper cover pin type retainers SECTION 501 19 Bumpers 2003 Mustang Workshop Manual ...

Page 3970: ...e four headlamp mounting clips 6 Disconnect the parking lamp and the headlamp electrical connectors two each and remove the two headlamps 7 Remove the pin type retainers 8 If equipped remove the pin type retainers ...

Page 3971: ...9 If equipped disconnect the fog lamp electrical connectors 10 Lift up on the tabs and remove the front bumper cover 11 To install reverse the removal procedure ...

Page 3972: ...e the luggage compartment trim panel covers 2 Remove the seven rear bumper cover nuts 3 Remove the fuel drain hose 4 Remove the four bumper cover screws two each side 5 Remove the pin type retainers and the rear bumper cover SECTION 501 19 Bumpers 2003 Mustang Workshop Manual ...

Page 3973: ...6 To install reverse the removal procedure ...

Page 3974: ...air cooler For additional information refer to Section 303 12 All vehicles 3 Remove the two rivets and the front bumper isolator Cobra 4 NOTE The charge air cooler bracket is removed for clarity Remove the four bolts and the two intercooler radiator brackets All vehicles 5 Remove the bolts and the front bumper SECTION 501 19 Bumpers 2003 Mustang Workshop Manual Special Tool s Heavy Duty Riveter 50...

Page 3975: ...6 To install reverse the removal procedure ...

Page 3976: ...ation refer to Rear Bumper Cover in this section 2 Remove the rear bumper cover isolator Vehicles with 4 6L engines 3 Remove the bolts and the exhaust outlet pipe bumper bracket All vehicles 4 Remove the rear bumper brace and tongue bolts 5 Remove the bolts and the rear bumper SECTION 501 19 Bumpers 2003 Mustang Workshop Manual ...

Page 3977: ...6 To install reverse the removal procedure ...

Page 3978: ...n Nm lb ft D Ring bolt 40 30 Front safety belt retractor bolt convertible only 30 22 Front safety belt retractor nut convertible only 30 22 Safety belt retractor bolt 40 30 Safety belt buckle to seat frame nut 40 30 Safety belt buckle to floorpan bolt 40 30 Safety belt anchor bolt 40 30 Tether anchor bolts 20 15 ...

Page 3979: ...utboard passengers operates in two ways 1 In the vehicle sensitive emergency locking mode the shoulder belt retractor will allow the occupant freedom of movement locking tightly only on hard braking hard cornering or impacts of approximately 8 km h 5 mph or more The front and rear outboard safety belt retractors can also be made to lock by pulling jerking on the belt 2 In the automatic locking mod...

Page 3980: ...ipped child safety seats have two lower attachments that connect to the vehicle portion of the LATCH system The vehicle portion of the system consists of two attachment points 6 mm wires bolted to the floor pan at both second row outboard seating positions The attachment points protrude from the biteline between the seat cushion and seat backrest If a child safety seat was in use during a collisio...

Page 3981: ... to specification Otherwise the child s safety seat may not be correctly secured and the child could be injured in case of a sudden stop or accident Instructions for installing the child safety belt anchor tether kit are included in the kit with the tether attachment ...

Page 3982: ...SECTION 501 20A Safety Belt System 2003 Mustang Workshop Manual Visual Inspection Chart Mechanical Electrical Inspect the safety belt webbing for integrity Open fuse Bare broken or disconnected wire Connector not tightly engaged Safety belt warning indicator lamp burned out or broken Symptom Chart Condition Possible Sources Action The safety belt warning chime does not operate the safety belt warn...

Page 3983: ...eveals an obvious concern s that can be readily identified service as required Do not attempt to carry out any repair on the buckle and tongue assembly If a concern exists with either component a new safety belt buckle and safety belt and retractor assembly must be installed Functional Test II Retractor The safety belt and retractor assembly must be freely operational for extraction and retraction...

Page 3984: ...r if the RH front or rear safety belts are to be tested 6 CAUTION Before installing a new safety belt assembly inspect the mounting area for damage and distortion If the retractor of a new safety belt assembly has been bolted into a damaged or distorted mounting area the retractor could be warped and may not function If this is the case remove the retractor and return the sheet metal to the origin...

Page 3985: ...Pull on the shoulder belt to check that the belt has remained in the ALR mode If the belt is not locked install a new safety belt and retractor assembly 7 Unlatch the safety belt tongue from the buckle and allow the safety belt to retract to its stowed position 8 Pull the shoulder belt to verify the retractor assembly has converted automatically out of the ALR mode If the shoulder belt remains loc...

Page 3986: ...or re dye the webbing as the webbing may weaken Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery or carpets Follow the instructions provided with the soap SECTION 501 20A Safety Belt System 2003 Mustang Workshop Manual ...

Page 3987: ...stalled if either damage or incorrect operation is noted 1 The safety belt assemblies should be periodically inspected to make sure that they have not become damaged and that they remain in correct operating condition particularly if they have been subjected to severe stress 2 Before installing the new safety belt assembly the safety belt retaining areas must be inspected for damage and distortion...

Page 3988: ...ed bolt 2 Drill out the internal threads in the safety belt anchor plate with a 27 64 inch drill bit 3 Rethread the anchor plate with a 1 2 13 tap 4 Blow out the chips 5 NOTE New parts are to be used in place of the original parts refer to the Parts Replacement Chart Safety Belt with Damaged Weld Nut Anchor Plate Threads in Specifications in this section Install the attachment parts in the correct...

Page 3989: ...6 inch diameter access holes adjacent to the weld nut clearance hole 3 Thread a length of copper welding wire through the clearance hole and position to secure the weld nut and washer 4 Use MIG wire feed welder and plug weld a 7 16 inch weld nut and standard washer in place at the two 8 mm 5 16 inch holes 5 Metal finish as necessary 6 Install the restraint system 7 Carry out the Functional Test Fo...

Page 3990: ...e and operate correctly Safety belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted 1 Before installing a new safety belt assembly the safety belt attaching areas must be inspected for damage and distortion If the attaching points are damaged and distorted the sheet metal must be worked back to its orig...

Page 3991: ...cess belt webbing back through the upper slot in the belt tongue 4 Grasp the belt tongue and pull the belt webbing up to form a loop through the low slot in the tongue 5 Rotate and fold the belt webbing over itself within the slot to remove the twist 6 Pull the excess belt webbing through the slot 7 NOTE Dual slot tongue shown single slot tongue is similar The safety belt tongue should face inward...

Page 3992: ......

Page 3993: ...to Section 501 05 2 Using the special tool remove the bolt and the safety belt retractor Remove the mastic seal 3 Using the special tool remove the safety belt anchor bolt 4 Using the special tool remove the D ring bolt SECTION 501 20A Safety Belt System 2003 Mustang Workshop Manual Special Tool s Torx Bit Safety Belt Bolt 501 010 T77L 2100 A ...

Page 3994: ...llation of the retractor into the vehicle The clip must be removed after the retractor is installed 2 Position the safety belt anchor Using the special tool install the safety belt bolt 3 Install a new mastic seal around the safety belt retractor before installing the retractor in the vehicle 4 Position the safety belt retractor Using the special tool install the bolt ...

Page 3995: ...e D ring bolt 6 Install the quarter trim panel For additional information refer to Section 501 05 7 The shoulder belt must pass through the belt holder on the top of the seatback 8 Check the active restraint system for correct operation ...

Page 3996: ......

Page 3997: ...tractor Installation NOTE Make sure the safety belt is not twisted 1 The shipping clip must remain attached prior to the installation of the retractor into the vehicle The clip must be removed after the retractor is installed 2 Position the safety belt retractor Install the nut and bolts SECTION 501 20A Safety Belt System 2003 Mustang Workshop Manual Special Tool s Torx Bit Safety Belt Bolt 501 01...

Page 3998: ...lder belt must pass through the belt holder on the top of the seatback 4 Install the quarter trim panel For additional information refer to Section 501 05 5 Check the active restraint system for correct operation ...

Page 3999: ...ng trim For additional information refer to Section 501 05 2 Using the special tool remove the D ring bolt 3 Using the special tool remove the bolt and the safety belt retractor 611B68 4 Remove the bolt SECTION 501 20A Safety Belt System 2003 Mustang Workshop Manual Special Tool s Torx Bit Safety Belt Bolt 501 010 T77L 2100 A ...

Page 4000: ...ke sure the safety belt is not twisted when inserting it in the quarter trim panel 1 Install the bolt 2 Using the special tool install the safety belt retractor and the bolt 3 Using the special tool install the D ring bolt ...

Page 4001: ...nel 31012 and the angel wing trim For additional information refer to Section 501 05 5 Make sure the shoulder belt passes through the belt holder on the top of the seatback 6 Check the active restraint system for correct operation ...

Page 4002: ... compartment front lining board 45444 3 Release the safety belt guide 4 Using the special tool remove the safety belt anchor bolt 5 Using the special tool remove the bolt and the rear safety belt retractor SECTION 501 20A Safety Belt System 2003 Mustang Workshop Manual Special Tool s Torx Bit Safety Belt Bolt 501 010 T77L 2100 A ...

Page 4003: ...n inserting it in the quarter trim panel 1 Using the special tool install the bolt and the rear safety belt retractor 2 Using the special tool install the safety belt anchor bolt 3 Install the safety belt guide 4 Install the luggage compartment front lining board ...

Page 4004: ...5 Install the rear seat cushion 6 Make sure the shoulder belt passes through the belt holder on the top of the seatback 7 Check the active restraint system for correct operation ...

Page 4005: ... metal to its original condition and structural integrity The convertible model tether anchors are part of the sheet metal These are accessed through the trunk by removing the trunk front trim Hard top only 4 NOTE Rework the sheet metal to its original condition and structural integrity To install reverse the removal procedure Hard top and convertible 5 Check the restraint system for correct opera...

Page 4006: ......

Page 4007: ...e front seat For additional information refer to Section 501 10 2 Remove the nut and the safety belt buckle Driver seat only 3 Disconnect the safety belt buckle electrical connector Installation 1 To install reverse the removal procedure SECTION 501 20A Safety Belt System 2003 Mustang Workshop Manual ...

Page 4008: ...2 Check the restraint system for correct operation ...

Page 4009: ...or plates Make sure correct part is used when installing buckle and anchor plate in the anchor locator feature NOTE LH rear seat safety belt buckle anchor plate shown To install reverse the removal procedure 2 Make sure the safety belt buckles are routed correctly and are placed through the seat cushion 3 Check the restraint system for correct operation SECTION 501 20A Safety Belt System 2003 Must...

Page 4010: ......

Page 4011: ...nchor LATCH Removal and Installation 1 Remove the lower anchors and tethers for children LATCH attachment fasteners 2 Remove the LATCH attachment 3 To install reverse the removal procedure SECTION 501 20A Safety Belt System 2003 Mustang Workshop Manual ...

Page 4012: ...orkshop Manual Torque Specifications Description Nm lb ft lb in Restraints control module bracket bolts 12 9 Driver air bag bolts 9 80 Passenger air bag bolts 9 80 Crash sensor grounding screw N802455 S190 Weld nut repair screw 8 mm 15 11 Grounding screw 6 mm N806327 S190 12 9 ...

Page 4013: ... is necessary to obtain the best occupant protection and to receive the full advantages of the SRS The air bag supplemental restraint system SRS components are shown in the following illustration Air Bag Supplemental Restraint System SRS Components SECTION 501 20B Supplemental Restraint System 2003 Mustang Workshop Manual Item Part Number Description 1 044A74 Passenger air bag module 2 14B321 Rest...

Page 4014: ...ator to indicate the lamp fault code LFC detected communicates through the data link connector DLC the current or historical diagnostic trouble codes DTCs signals the generic electronic module GEM to activate a chime if the air bag indicator is not available and another SRS fault exists NOTE The safing sensor is internal to the RCM and is not repaired separately The RCM monitors the SRS for possib...

Page 4015: ...und cable is disconnected Electrical System The electrical system that supports the air bag supplemental restraint system SRS is powered from the battery through the ignition circuit provides the electrical path from the restraints control module RCM to the air bag modules provides the electrical path from the RCM to the air bag indicator provides the electrical path from the RCM to the data link ...

Page 4016: ......

Page 4017: ...ction of the pinpoint test for the DTC involved Follow the deactivation procedure in this section Determine the location of components involved in creating that code Perform a thorough visual inspection of components connectors splices and wiring harnesses pinched wires worn insulation on conductors Refer to the Possible Causes section of the pinpoint test for the DTC involved which lists the comm...

Page 4018: ...The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non deployment in a collision resulting in possible personal injury NOTE Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle Prior to attempting to diagnose or repair a seat concern when equippe...

Page 4019: ...raint system diagnostic tool to the vehicle harness at the top of the steering column 5 Disconnect the passenger air bag module electrical connector 6 WARNING The restraint system diagnostic tool is for restraint system service only Remove from vehicle prior to road use Failure to remove could result in injury and possible violation of vehicle safety standards Connect a restraint system diagnostic...

Page 4020: ...ules or restraint system diagnostic tools installed The air bag indicator will light continuously for approximately six seconds and then turn off If an air bag supplemental restraint system SRS fault is present the air bag indicator will either fail to light remain lit continuously flash The flashing might not occur until approximately 30 seconds after the ignition switch has been turned from the ...

Page 4021: ...to reconnect all system components Refer to Air Bag System Reconnect Checklist in this section Install a New Component Install a new component means to remove the existing component and install a new authorized part obtained from Ford Customer Service Division Verify the System Verify the system means to prove out the system with restraint system diagnostic tools for the air bag modules in place o...

Page 4022: ......

Page 4023: ...lways repair the current DTCs first 4 If memory displays different continuous DTCs than the On Demand Self Test perform in the following order On Demand Self Test Memory Retrieve Clear Continuous DTCs A DTC can indicate several concerns The DTCs are to assist in system diagnosis and are not to be considered definitive Always refer to the pinpoint test corresponding to the DTC to determine where th...

Page 4024: ... DTCs and if any remain they will be displayed Hard DTCs will be redisplayed after clearing DTCs since they cannot be cleared from the RCM On Demand Self Test The On Demand Self Test option is used to verify that no electrical concerns exist with the air bag supplemental restraint system SRS Upon entering the self test the restraints control module RCM will make an electrical check of each electri...

Page 4025: ...inpoint Test B C1414 29 5 Incorrect Vehicle Identification Code Go To Pinpoint Test C B1887 15 6 Driver Air Bag Circuit Shorted to Ground Go To Pinpoint Test D B1916 15 7 Driver Air Bag Circuit Shorted to Battery or Ignition Go To Pinpoint Test E B1888 16 8 Passenger Air Bag Circuit Shorted to Ground Go To Pinpoint Test F B1925 16 9 Passenger Air Bag Circuit Shorted to Battery or Ignition Go To Pi...

Page 4026: ... possible violation of vehicle safety standards If the on demand self test is passed and no DTCs are retrieved GO to Symptom Chart 5 If DTCs are retrieved proceed to the Restraints Control Module RCM Diagnostic Trouble Code DTC Priority Table Symptom Chart No Communication with the Restraints Control Module Go To Pinpoint Test P Visual Inspection Chart Mechanical Electrical Damaged restraints cont...

Page 4027: ...restraints control module Data Link Connector DLC RCM Circuitry Test P ...

Page 4028: ...ontinuously for 6 seconds after the ignition switch is placed in the RUN position and after five cycles of a lamp fault code LFC if a fault exists Be sure to cycle the ignition switch and look for a 6 second indicator prove out without LFCs The restraints control module RCM will communicate diagnostic trouble codes DTCs to the scan tool through the data link connector DLC If the scan tool displays...

Page 4029: ...o the Restraints Control Module RCM Diagnostic Trouble Code DTC Priority Table in this section for pinpoint test direction No GO to A2 A2 CHECK THE RCM CONNECTION WARNING If the supplemental restraint system SRS is being serviced the system must be deactivated and restraint system diagnostic tools must be installed Refer to Air Bag Supplemental Restraint System SRS in this section The air bag rest...

Page 4030: ... locking tab is engaged Is RCM C2041 fully connected and are the red locking tabs engaged A3 CHECK THE RCM CONNECTOR Key in OFF position Disconnect RCM C2041 Inspect C2041 component side for a worn or damaged camming beam Inspect for foreign material NOTE The shorting bars can be accessed by prying out the blue cover from the harness side of the connector Inspect C2041 harness side for worn damage...

Page 4031: ...O GROUND Connect RCM C2041 Disconnect Instrument Cluster C220a Measure the resistance to ground at instrument cluster C220a pin 12 circuit 608 BK YE harness side Is the resistance less than 10 000 ohms Yes REPAIR the circuit GO to A7 No INSTALL a new RCM GO to A7 A7 CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step A1 Were any continuous DTCs retrieved during Step A1 Yes ...

Page 4032: ...ing bolts incorrect tightening torque of the RCM retaining bolts high resistance on RCM logic ground circuit 397 BK WH PINPOINT TEST B LFC 21 DTC B1921 RCM BRACKET GROUND RESISTANCE HIGH section for pinpoint test direction No RECONNECT the system REACTIVATE the system PROVE OUT the system REFER to Air Bag Supplemental Restraint System SRS in this section CLEAR all DTCs Test Step Result Action to T...

Page 4033: ...ounting surface are free of damage corrosion or dirt and the three retaining bolts are fully seated and correctly tightened Reattach the RCM and mounting bracket to the mounting surface GO to B7 No GO to B3 B3 CHECK THE RCM HARNESS CONNECTION Check the RCM harness connection Is the RCM harness connector connected to the RCM correctly Yes GO to B4 No ATTACH the RCM harness connector correctly GO to...

Page 4034: ...ECT VEHICLE IDENTIFICATION CODE Was the continuous DTC retrieved during Step B1 an intermittent fault CHECK for causes or intermittent high resistance on circuit 397 BK WH Attempt to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently REPAIR any intermittent concerns found GO to B7 No GO to B7 B7 CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorde...

Page 4035: ...concern when equipped with a seat side air bag the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors The restraint system diagnostic tools must be removed prior to operating the vehicle over the road NOTE After diagnosing or repairing an SRS the restraint system diagnostic tools must be removed before op...

Page 4036: ...tep C1 an intermittent fault or were you directed to this step from Step C4 Yes CHECK for causes of an intermittent open on circuit 611 WH OG Attempt to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently REPAIR any intermittent concerns found GO to C6 No GO to C6 C6 CHECK FOR ADDITIONAL DTCs Refer to continuous DTCs recorded during Step C1 Were any continuo...

Page 4037: ...nternal concern PINPOINT TEST D LFC 15 DTC B1887 DRIVER AIR BAG CIRCUIT SHORTED TO GROUND system PROVE OUT the system REFER to Air Bag Supplemental Restraint System SRS in this section CLEAR all DTCs Test Step Result Action to Take D1 CHECK FOR A HARD OR INTERMITTENT DTC Key in OFF position Connect the diagnostic tool Scan Tool Key in ON position Enter the following diagnostic mode on the diagnost...

Page 4038: ...system the restraint system diagnostic tools must be removed before operating the vehicle over the road NOTE The SRS must be fully operational and free of faults before releasing the vehicle to the customer Key in OFF position Deactivate the system Refer to Air Bag Supplemental Restraint System SRS in the Diagnosis and Testing portion of this section Key in OFF position Key in ON position Enter th...

Page 4039: ...Was the continuous DTC retrieved during Step D1 an intermittent fault Yes CHECK for causes of intermittent short to ground on circuit 614 GY OG circuit 615 GY WH and the clockspring assembly Attempt to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently REPAIR any intermittent concerns found GO to D6 No GO to D6 D6 CHECK FOR ADDITIONAL DTCs Refer to continuo...

Page 4040: ... present at this time GO to E5 E2 CHECK THE DRIVER AIR BAG MODULE WARNING If the supplemental restraint system SRS is being serviced the system must be deactivated and restraint system diagnostic tools must be installed Refer to Air Bag Supplemental Restraint System SRS in this section The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system...

Page 4041: ...n RCM C2041 pin 4 circuit 615 GY WH harness side Are the voltages less than 0 2 volt Yes INSTALL a new RCM GO to E6 No GO to E4 E4 CHECK THE DRIVER AIR BAG MODULE WIRING AND THE CLOCKSPRING Disconnect Clockspring C218b Inspect all crimps terminals wires and connectors in circuit 614 GY OG feeding the RCM pin 3 circuit 615 GY WH feeding pin 4 and the clockspring C218b Check for pinched wires and da...

Page 4042: ...used by a short to ground on circuit 607 LB OG a short to ground on circuit 616 PK BK a short to ground on the passenger air bag module an RCM internal concern PINPOINT TEST F LFC 16 DTC B1888 PASSENGER AIR BAG CIRCUIT SHORTED TO GROUND to E6 No GO to E6 E6 CHECK FOR ADDITIONAL DTCs Refer to continuous DTCs recorded during Step E1 Were any continuous DTCs retrieved during Step E1 Yes Do not clear ...

Page 4043: ...side air bag with the seat in the vehicle Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag electrical connectors The restraint system diagnostic tools must be removed prior to operating the vehicle over the road NOTE After dia...

Page 4044: ...s the continuous DTC retrieved during Step F1 an intermittent fault Yes CHECK for causes of intermittent short to ground on circuit 607 LB OG and circuit 616 PK BK Attempt to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently REPAIR any intermittent concerns found GO to F6 No GO to F6 F6 CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during...

Page 4045: ...odule an RCM internal concern PINPOINT TEST G LFC 16 DTC B1925 PASSENGER AIR BAG CIRCUIT SHORTED TO BATTERY OR IGNITION REACTIVATE the system PROVE OUT the system REFER to Air Bag Supplemental Restraint System SRS in this section CLEAR all DTCs Test Step Result Action to Take G1 CHECK FOR A HARD OR INTERMITTENT DTC Key in OFF position Connect the diagnostic tool Scan Tool Key in ON position Enter ...

Page 4046: ...t system the restraint system diagnostic tools must be removed before operating the vehicle over the road NOTE The SRS must be fully operational and free of faults before releasing the vehicle to the customer Key in OFF position Deactivate the system Refer to Air Bag Supplemental Restraint System SRS in the Diagnosis and Testing portion of this section Key in OFF position Key in ON position Enter ...

Page 4047: ...uring Step G1 an intermittent fault Yes CHECK for causes of intermittent short to battery or ignition on circuit 607 LB OG and circuit 616 PK BK Attempt to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently REPAIR any intermittent concerns found GO to G6 No GO to G6 G6 CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step G1 Were any c...

Page 4048: ... retrieved during the on demand self test GO to H2 No This is an intermittent fault The fault condition is not present at this time GO to H5 H2 CHECK THE DRIVER AIR BAG MODULE WARNING If the supplemental restraint system SRS is being serviced the system must be deactivated and restraint system diagnostic tools must be installed Refer to Air Bag Supplemental Restraint System SRS in this section The...

Page 4049: ...rcuit 614 GY OG and circuit 615 GY WH of the RCM connector are shorted together with a shorting bar Do not remove the shorting bar NOTE Zero the multimeter prior to taking the measurement Measure the resistance between driver air bag C216 circuit 614 GY OG harness side and driver air bag C216 circuit 615 GY WH harness side Is the resistance greater than 0 5 ohm Yes GO to H4 No INSTALL a new RCM GO...

Page 4050: ...intermittent fault CHECK for causes of intermittent high resistance on circuit 614 GY OG circuit 615 GY WH and the clockspring assembly Attempt to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently REPAIR any intermittent concerns found GO to H6 No GO to H6 H6 CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step H1 Were any continuous...

Page 4051: ...e deactivated and restraint system diagnostic tools must be installed Refer to Air Bag Supplemental Restraint System SRS in this section The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non deployment in a collision resulting in possible personal injury NOTE Diagnostics or repairs are not to be performed on a ...

Page 4052: ...LB OG harness side and passenger air bag C256 circuit 616 PK BK harness side Is the resistance greater than 0 5 ohm Yes REPAIR the circuit s as necessary GO to I5 No INSTALL a new RCM GO to I5 I4 CHECK FOR AN INTERMITTENT FAULT Refer to the continuous DTCs recorded during Step I1 Was the continuous DTC retrieved during Step I1 an intermittent fault Yes CHECK for causes of intermittent high resista...

Page 4053: ...r camming beam PINPOINT TEST J LFC 34 DTC B1934 DRIVER AIR BAG CIRCUIT RESISTANCE LOW Trouble Code DTC Priority Table in this section for pinpoint test direction No RECONNECT the system REACTIVATE the system PROVE OUT the system REFER to Air Bag Supplemental Restraint System SRS in this section CLEAR all DTCs Test Step Result Action to Take J1 CHECK FOR A HARD OR INTERMITTENT DTC Key in OFF positi...

Page 4054: ... restraint system diagnostic tools must be removed prior to operating the vehicle over the road NOTE After diagnosing or repairing an SRS the restraint system diagnostic tools must be removed before operating the vehicle over the road NOTE After diagnosing or repairing a seat system the restraint system diagnostic tools must be removed before operating the vehicle over the road NOTE The SRS must b...

Page 4055: ...nce on circuit 614 GY OG circuit 615 GY WH and the clockspring assembly Attempt to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently REPAIR any intermittent concerns found GO to J6 No GO to J6 J6 CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step J1 Were any continuous DTCs retrieved during Step J1 Yes Do not clear any DTCs until a...

Page 4056: ...ction to Take K1 CHECK FOR A HARD OR INTERMITTENT DTC Key in OFF position Connect the diagnostic tool Scan Tool Key in ON position Enter the following diagnostic mode on the diagnostic tool Retrieve Clear Continuous DTCs Retrieve and record any continuous DTCs for use later in this pinpoint test Enter the following diagnostic mode on the diagnostic tool On Demand Self Test Was DTC B1935 retrieved ...

Page 4057: ...t be fully operational and free of faults before releasing the vehicle to the customer Key in OFF position Deactivate the system Refer to Air Bag Supplemental Restraint System SRS in the Diagnosis and Testing portion of this section Key in OFF position Key in ON position Enter the following diagnostic mode on the diagnostic tool On Demand Self Test Was DTC B1935 retrieved passenger air bag module ...

Page 4058: ...aused by a short to ground or open on circuit 1083 LB BK a damaged or inoperative GEM PINPOINT TEST L DTC B1892 AIR BAG TONE WARNING INDICATOR CIRCUIT SHORTED TO GROUND OR OPEN concerns found GO to K5 No GO to K5 K5 CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded during Step K1 Were any continuous DTCs retrieved during Step K1 Yes Do not clear any DTCs until all DTCs have been reso...

Page 4059: ...collision resulting in possible personal injury NOTE Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag the seat must be removed from the vehicle and the restraint system diagnostic tools must be installed in the seat side air bag elec...

Page 4060: ... side and GEM C201e pin 10 circuit 1083 LB BK harness side Is the resistance greater than 10 ohms Yes REPAIR the circuit GO to L6 No GO to L4 L4 CHECK THE AIR BAG TONE WARNING INDICATOR Disconnect GEM C201e Key in ON position Measure the voltage between RCM C2041 pin 26 circuit 1083 LB BK harness side and ground Yes INSTALL a new GEM GO to L6 No INSTALL a new RCM GO to L6 ...

Page 4061: ...ing Step L1 Was the continuous DTC retrieved during Step L1 an intermittent fault Yes CHECK for causes of intermittent short to ground or open on circuit 1083 LB BK Attempt to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently REPAIR any intermittent concerns found GO to L6 No GO to L6 L6 CHECK FOR ADDITIONAL DTCs Refer to the continuous DTCs recorded durin...

Page 4062: ...restraint system SRS is being serviced the system must be deactivated and restraint system diagnostic tools must be installed Refer to Air Bag Supplemental Restraint System SRS in this section The air bag restraint system diagnostic tools must be removed and the air bag modules reconnected when the system is reactivated to avoid non deployment in a collision resulting in possible personal injury N...

Page 4063: ...F position Connect GEM C201e Key in ON position Jumper RCM C2041 pin 26 circuit 1083 LB BK harness side to ground Does the GEM generate a tone Yes INSTALL a new RCM GO to M5 No INSTALL a new GEM GO to M5 M4 CHECK FOR AN INTERMITTENT FAULT Refer to continuous DTCs recorded during Step M1 Was the continuous DTC retrieved during step M1 an intermittent fault Yes Check for causes of intermittent short...

Page 4064: ... an air bag indicator failure in addition to another SRS failure the RCM will send a signal to the generic electronic module GEM to produce five sets of five tone bursts Possible Causes An air bag indicator inoperative condition can be caused by a damaged wiring on circuit 608 BK YE a damaged or burned out air bag indicator worn or damaged instrument cluster an RCM internal concern PINPOINT TEST N...

Page 4065: ...em is reactivated to avoid non deployment in a collision resulting in possible personal injury NOTE Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with the seat in the vehicle Prior to attempting to diagnose or repair a seat concern when equipped with a seat side air bag the seat must be removed from the vehicle and the restraint system diagnostic tools ...

Page 4066: ...a pin 12 circuit 608 BK YE Is the resistance less than 100 ohms Yes REPAIR the circuit GO to N6 No GO to N4 N4 CHECK CIRCUIT 608 BK YE FOR AN OPEN Disconnect Instrument Cluster C220a Measure the resistance between RCM C2041 pin 20 circuit 608 BK YE harness side and instrument cluster C220a pin 12 circuit 608 BK YE harness side Yes REPAIR the circuit GO to N6 No REPAIR the instrument cluster GO to ...

Page 4067: ... 10 ohms N5 CHECK FOR AN INTERMITTENT FAULT Refer to the continuous DTCs recorded during Step N1 Was the continuous DTC retrieved during Step N1 an intermittent fault Yes CHECK for causes of intermittent short to ground or open on circuit 608 BK YE Attempt to recreate the hard fault by flexing the wire harness and cycling the ignition key frequently REPAIR any intermittent concerns found GO to N6 ...

Page 4068: ... is a hard fault The fault condition is still present This fault cannot be cleared until it is corrected and the DTC is no longer retrieved during the on demand self test GO to O2 No This is an intermittent fault The fault condition is not present at this time GO to O4 O2 CHECK THE AIR BAG INDICATOR CIRCUIT WARNING If the supplemental restraint system SRS is being serviced the system must be deact...

Page 4069: ... O3 CHECK AIR BAG INDICATOR CIRCUIT FOR SHORT TO BATTERY Key in OFF position Disconnect RCM C2041 Disconnect Instrument Cluster C220a Key in ON position Measure the voltage between RCM C2041 pin 20 circuit 608 BK YE harness side and ground Is the voltage less than 0 2 volt Yes REPAIR the instrument cluster GO to O5 No REPAIR the circuit GO to O5 O4 CHECK FOR AN INTERMITTENT FAULT Refer to the cont...

Page 4070: ...Table in this section for pinpoint test direction No RECONNECT the system REACTIVATE the system PROVE OUT the system REFER to Air Bag Supplemental Restraint System SRS in this section CLEAR all DTCs Test Step Result Action to Take P1 CHECK THE RCM CONNECTOR C2041 AND CONNECTOR PIN 5 FOR DAMAGE WARNING If the supplemental restraint system SRS is being serviced the system must be deactivated and res...

Page 4071: ... free of faults before releasing the vehicle to the customer Key in OFF position Deactivate the system Refer to Air Bag Supplemental Restraint System SRS in the Diagnosis and Testing portion of this section Key in OFF position Disconnect RCM C2041 Inspect RCM C2041 harness side and RCM C2041 component side pin 5 for damage Are RCM C2041 and RCM C2041 pin 5 OK REACTIVATE the system P2 CHECK THE DLC...

Page 4072: ...5 CHECK CIRCUIT 70 LB WH FOR AN OPEN Measure the resistance between RCM C2041 pin 5 circuit 70 LB WH harness side and DLC C251 pin 7 circuit 70 LB WH harness side Is the resistance less than 5 ohms Yes INSTALL a new RCM RETEST the communication to RCM RECONNECT the system REACTIVATE the system PROVE OUT the system REFER to Air Bag Supplemental Restraint System SRS in this section No REPAIR the cir...

Page 4073: ......

Page 4074: ...cle over the road NOTE The SRS must be fully operational and free of faults before releasing the vehicle to the customer 1 When any deployable device driver air bag passenger air bag seat side air bag safety belt pretensioner etc or combination of devices are deployed and or the RCM has the DTC B1231 Crash Data Memory Full in memory the repair of the vehicle s supplemental restraint system SRS is ...

Page 4075: ......

Page 4076: ...raint system SRS vehicle and when handling an air bag module This will reduce the risk of injury in the event of an accidental deployment Dispose of the deployed air bag modules and safety belt pretensioners in the same manner as any other part to be scrapped SECTION 501 20B Supplemental Restraint System 2003 Mustang Workshop Manual ...

Page 4077: ...All inoperative air bag modules and safety belt pretensioners have been placed on the Mandatory Return List All discolored or damaged air bag modules must be treated the same as any inoperative live air bag being returned 1 Remove the inoperative component from the vehicle For additional information refer to the appropriate air bag procedure in this section 2 NOTE When installing a new air bag mod...

Page 4078: ......

Page 4079: ...rs with all personnel at least 6 1 meters 20 feet away to ensure personal safety Due to the loud report which occurs when the air bag is deployed hearing protection is required WARNING Do not place the driver or passenger air bag module with the trim cover or deployment door facing down as the forces of the deploying air bag can cause it to ricochet and cause personal injury 1 Remove the driver ai...

Page 4080: ...rs 20 feet away from the air bag module 6 Deploy the air bag module by touching the other ends of the two wires to the terminals of a 12 volt battery 7 To allow for cooling wait at least ten minutes before approaching the deployed air bag 8 Dispose of the deployed air bag module in the same manner as any other part to be scrapped ...

Page 4081: ......

Page 4082: ...h all personnel at least 6 1 meters 20 feet away to ensure personal safety Due to the loud report which occurs when the air bag is deployed hearing protection is required WARNING Do not place the driver or passenger air bag module with the trim cover or deployment door facing down as the forces of the deploying air bag can cause it to ricochet and cause personal injury 1 Remove the passenger air b...

Page 4083: ...ters 20 feet away from the air bag module 6 Deploy the air bag module by touching the other ends of the two wires to the terminals of a 12 volt battery 7 To allow for cooling wait at least ten minutes before approaching the deployed air bag 8 Dispose of the deployed air bag module in the same manner as any other part to be scrapped ...

Page 4084: ......

Page 4085: ...ag module Doing so can result in air bag deployment which can result in personal injury WARNING The safety belt buckle pretensioner and safety belt retractor pretensioner are pyrotechnic devices Never probe a pretensioner electrical connector Doing so could result in pretensioner or air bag deployment and could result in personal injury WARNING Vehicle sensor orientation is critical for proper sys...

Page 4086: ... road NOTE The SRS must be fully operational and free of faults before releasing the vehicle to the customer 1 WARNING To avoid accidental deployment and possible personal injury the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system SRS components and before servicing replacing adjusting or striking components near the front ...

Page 4087: ...ase of the steering column 5 Attach the restraint system diagnostic tool to the vehicle harness side of the clockspring electrical connector 6 Open the glove compartment push in on the tabs and open the glove compartment door to its fullest extent 7 Remove the right hand A C register duct ...

Page 4088: ...e supplemental restraint system SRS For additional information refer to Air Bag Supplemental Restraint System SRS in the Diagnosis and Testing portion of this section 12 Disconnect the battery ground cable and wait at least one minute For additional information refer to Section 414 01 Reactivation WARNING To reduce the risk of serious personal injury read and follow all warnings cautions and notes...

Page 4089: ... Connect the A C duct at the air plenum Install the duct at the A C register and install the two screws 5 Close the glove compartment 6 Remove the restraint system diagnostic tool from the clockspring electrical connector 7 Connect the clockspring electrical connector at the base of the steering column ...

Page 4090: ...he battery ground cable For additional information refer to Section 414 01 11 WARNING The restraint system diagnostic tool is for restraint system service only Remove from vehicle prior to road use Failure to remove could result in injury and possible violation of vehicle safety standards With all the restraint system diagnostic tools removed prove out the supplemental restraint system SRS For add...

Page 4091: ......

Page 4092: ... having missing restraints control module attaching weld nut s Read both procedures before proceeding with the repair NOTE If two or more weld nuts are missing do not install the J nuts as outlined in this procedure Weld nuts must be installed as outlined in Weld Nut Repair Missing Weld Nut Restraints Control Module RCM NOTE The following procedure applies to vehicles that have a rectangular hole ...

Page 4093: ......

Page 4094: ...able and wait at least one minute Be sure to disconnect auxiliary batteries and power supplies if equipped NOTE There are two procedures to repair a vehicle having missing restraints control module attaching weld nut s Read both procedures before proceeding with the repair NOTE If two or more weld nuts are missing do not install the J nuts as outlined in Weld Nut Repair J Nut Restraints Control Mo...

Page 4095: ... weld nut clearance hole firmly pulling on the copper welding wire allowing the secured flatwasher to hold the weld nut in position 8 Holding the weld nut securely in place and using a MIG welder weld in four places around the edge of the weld nut 9 Metal finish as required 10 Verify the nut is securely in place 11 Install the crash sensor 12 Tighten the attaching screws to specification For addit...

Page 4096: ...The side air bag sensors are located at or near the base of the B pillar To deplete the backup power supply energy disconnect the battery ground cable and wait at least one minute Be sure to disconnect auxiliary batteries and power supplies if equipped 1 Obtain an 8 mm 0 32 in grounding screw part number N802455 S190 2 Drill out the internal threads of the stripped out weld nut to 7 37 mm 0 29 in ...

Page 4097: ......

Page 4098: ...Failure to remove could result in injury and possible violation of vehicle safety standards CAUTION Electronic modules are sensitive to static electrical charges If exposed to these charges damage can result NOTE Repair is made by installing a new part only If the new part does not correct the condition install the original part and perform the diagnostic procedure again 1 Prepare the vehicle for ...

Page 4099: ...on of this section 2 Remove the right hand restraints control module RCM bracket retaining bolt 1 Position the carpet back at the right hand side of the instrument panel I P center support bracket 2 Remove the RCM bracket retaining bolt 3 Remove the RCM with bracket 1 Position the carpet back at the left hand side of the I P center support bracket 2 Disengage the RCM electrical connector locking c...

Page 4100: ...ditional information refer to Section 414 01 6 Restore the vehicle to operating condition 1 WARNING To reduce the risk of serious personal injury read and follow all warnings cautions notes and instructions in the supplemental restraint system SRS deactivation reactivation procedure Reactivate the supplemental restraint system SRS For additional information refer to Supplemental Restraint System S...

Page 4101: ...Restraint System SRS in the Diagnosis and Testing portion of this section ...

Page 4102: ... can result in personal injury WARNING Air bag modules with discolored or damaged trim covers must be replaced not repainted WARNING The restraint system diagnostic tool is for restraint system service only Remove from vehicle prior to road use Failure to remove could result in injury and possible violation of vehicle safety standards NOTE Repair is made by installing a new part only If the new pa...

Page 4103: ...on refer to Section 414 01 2 WARNING To reduce the risk of serious personal injury read and follow all warnings cautions notes and instructions in the supplemental restraint system SRS deactivation reactivation procedure Deactivate the supplemental restraint system SRS For additional information refer to Supplemental Restraint System SRS Deactivation and Reactivation in the General Procedures port...

Page 4104: ... the base of the steering column 6 Connect the clockspring electrical connector at the base of the steering column 7 Attach the restraint system diagnostic tool to the clockspring electrical connector at the top of the steering column 8 Connect the battery ground cable For additional information refer to Section 414 01 ...

Page 4105: ...ation WARNING To reduce the risk of serious personal injury read and follow all warnings cautions and notes at the beginning of the removal procedure 1 Disconnect the battery ground cable and wait at least one minute For additional information refer to Section 414 01 2 Remove the restraint system diagnostic tool from the clockspring electrical connector at the top of the steering column 3 Connect ...

Page 4106: ...onsole door latches strikers seats and hood latches Please refer to the appropriate vehicle shop manual to determine location of the front air bag sensors The side air bag sensors are located at or near the base of the B pillar To deplete the backup power supply energy disconnect the battery ground cable and wait at least one minute Be sure to disconnect auxiliary batteries and power supplies if e...

Page 4107: ... Failure to remove could result in injury and possible violation of vehicle safety standards With all the restraint system diagnostic tools removed prove out the supplemental restraint system SRS For additional information refer to Air Bag Supplemental Restraint System SRS in the Diagnosis and Testing portion of this section ...

Page 4108: ...which can result in personal injury WARNING Air bag modules with discolored or damaged trim covers must be replaced not repainted WARNING The restraint system diagnostic tool is for restraint system service only Remove from vehicle prior to road use Failure to remove could result in injury and possible violation of vehicle safety standards NOTE Repair is made by installing a new part only If the n...

Page 4109: ...ure Deactivate the supplemental restraint system SRS For additional information refer to Supplemental Restraint System SRS Deactivation and Reactivation in the General Procedures portion of this section 2 CAUTION Do not handle the passenger air bag module by grabbing the edges of the deployment doors Remove the passenger air bag module 1 Remove the passenger air bag module electrical connector fro...

Page 4110: ...able devices prove out the supplemental restraint system SRS For additional information refer to Air Bag Supplemental Restraint System SRS in the Diagnosis and Testing portion of this section 7 WARNING To avoid accidental deployment and possible personal injury the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system SRS compone...

Page 4111: ... the supplemental restraint system SRS deactivation reactivation procedure Reactivate the supplemental restraint system SRS For additional information refer to Supplemental Restraint System SRS Deactivation and Reactivation in the General Procedures portion of this section 2 WARNING The restraint system diagnostic tool is for restraint system service only Remove from the vehicle prior to road use ...

Page 4112: ... can result in personal injury WARNING Air bag modules with discolored or damaged trim covers must be replaced not repainted WARNING The restraint system diagnostic tool is for restraint system service only Remove from vehicle prior to road use Failure to remove could result in injury and possible violation of vehicle safety standards NOTE Repair is made by installing a new part only If the new pa...

Page 4113: ...on refer to Section 414 01 2 WARNING To reduce the risk of serious personal injury read and follow all warnings cautions notes and instructions in the supplemental restraint system SRS deactivation reactivation procedure Deactivate the supplemental restraint system SRS For additional information refer to Supplemental Restraint System SRS Deactivation and Reactivation in the General Procedures port...

Page 4114: ... rotation when the clockspring is removed 7 Remove the lower steering column shroud 3530 1 Remove the tilt wheel handle and shank 3F609 2 Remove the four screws 3 Remove the lower steering column shroud 8 Remove the ignition switch lock cylinder 11582 1 Position the ignition switch lock cylinder to the RUN position 2 Using the suitable tool push upward on the cylinder release tab while pulling the...

Page 4115: ...m PATS transmitter 1 Remove the PATS transmitter retaining screw 2 Position the PATS transmitter out of the way 11 Remove the key in ignition warning indicator switch 12 Remove the two clockspring electrical connectors from the bracket Disconnect the remaining electrical connector ...

Page 4116: ...sonal injury read and follow all warnings cautions and notes at the beginning of the removal procedure Vehicles receiving a new clockspring 1 NOTE A new clockspring is supplied in a centralized position and held there with a key Remove the key from the clockspring holding the rotor in its centralized position Do not allow the clockspring rotor to turn Vehicles needing clockspring recentering ...

Page 4117: ...on While holding the clockspring locking tab in the released position turn the rotor counterclockwise carefully feeling for the ribbon wire to run out of length and a slight resistance is felt Stop turning at this point 4 While holding the clockspring locking tab in the released position turn the clockspring clockwise approximately three turns This is the center point of the clockspring Release th...

Page 4118: ...nnector 6 Connect the two clockspring electrical connectors Position the clockspring electrical connectors onto the bracket 7 Install the key in ignition warning indicator switch 8 Install the passive anti theft system PATS transmitter 1 Position the PATS transmitter to the steering column 2 Install the screw ...

Page 4119: ...l the ignition switch lock cylinder Vehicle repairs reusing the same clockspring 11 Remove the tape applied during clockspring removal All vehicles 12 Install the lower steering column shroud 1 Position the lower steering column shroud 2 Install the screws ...

Page 4120: ... devices prove out the supplemental restraint system SRS For additional information refer to Air Bag Supplemental Restraint System SRS in the Diagnosis and Testing portion of this section 17 Disconnect the battery ground cable and wait at least one minute For additional information refer to Section 414 01 18 Remove the restraint system diagnostic tool from the clockspring electrical connector at t...

Page 4121: ...ditional information refer to Supplemental Restraint System SRS Deactivation and Reactivation in the General Procedures portion of this section 2 WARNING The restraint system diagnostic tool is for restraint system service only Remove from the vehicle prior to road use Failure to remove could result in injury and possible violation of vehicle safety standards With all the restraint system diagnost...

Page 4122: ......

Page 4123: ...bframe brace bolts 41 30 Front subframe support front and rear outboard bolts convertible vehicles only 63 46 Front subframe support rear inboard bolts convertible vehicles only 30 22 HEGO connector bracket nut 47 35 Rear subframe bolts 103 76 Transmission support insulator to transmission extension housing bolts 70 52 Transmission support insulator to rear engine support nut 70 52 Transmission su...

Page 4124: ...etrain operation Window glass cracks door and window opening concerns and air or water leaks at the doors are often caused by improperly tightened bolts and body misalignment Every structural member and outer panel is designed to offer the maximum protection in the event of a collision SECTION 502 00 Frame and Body Mounting 2003 Mustang Workshop Manual ...

Page 4125: ... measurements are made without trim and from metal to metal To check the body alignment take two opposite diagonal measurements between the front center or rear pillars Take the measurements between reference points such as crease lines or weld joints which are diagonally opposite each other on the two pillars being measured SECTION 502 00 Frame and Body Mounting 2003 Mustang Workshop Manual ...

Page 4126: ...4 750 in 2 1535 75 mm 61 43 in 3 1123 25 mm 44 93 in 4 1450 97 mm 57 125 in 5 420 68 mm 16 5622 in 6 1450 97 mm 57 125 in 7 1065 28 mm 41 9400 in 8 420 68 mm 16 5622 in 9 1141 41 mm 44 9373 in 10 857 00 mm 33 740 in 11 751 84 mm 29 600 in 12 1670 05 mm 62 750 in 13 1352 55 mm 53 250 in 14 1212 00 mm 47 716 in 15 802 40 mm 31 5905 in 16 802 40 mm 31 5905 in 17 717 55 mm 28 250 in ...

Page 4127: ...mm 20 500 in 20 792 16 mm 31 1873 in 21 992 18 mm 39 0621 in 22 863 60 mm 34 00 in 23 522 28 mm 20 5622 in 24 1219 20 mm 48 00 in 25 1454 15 mm 57 250 26 893 76 mm 35 1873 in 27 1484 31 mm 58 4373 in 28 792 16 mm 38 1873 in 29 819 15 mm 32 250 in 30 404 81 mm 15 9374 in 31 684 21 mm 26 9374 in 32 522 28 mm 20 5622 in 33 1181 10 mm 46 500 in 34 385 76 mm 15 1874 in 35 385 76 mm 15 1874 in 36 746 12...

Page 4128: ......

Page 4129: ...tion 204 01 Vehicles with convertible top 3 Remove the front subframe support For additional information refer to Subframe Support Convertible in this section Vehicles with hard top 4 Remove the front subframe brace Remove the bolts All vehicles 5 Lower the vehicle SECTION 502 00 Frame and Body Mounting 2003 Mustang Workshop Manual Special Tool s 3 Bar Engine Support Kit 303 F072 Lifting Bracket S...

Page 4130: ...6 Install the special tool 7 Install the special tool 8 Install the special tool 9 Raise and support the vehicle 10 Remove the LH engine mount nut ...

Page 4131: ... Remove the RH engine mount nut 12 Lower the vehicle 13 Using the special tool raise and support the engine 14 Raise the vehicle 15 Support the front subframe 16 Remove the four front subframe lower bolts ...

Page 4132: ...17 Remove the four front subframe upper bolts 18 NOTE Two technicians are needed to carry out this step Lower and remove the front subframe 19 To install reverse the removal procedure ...

Page 4133: ......

Page 4134: ...efer to Section 204 01 Vehicles with convertible top 3 Remove the front subframe support For additional information refer to Subframe Support Convertible in this section Vehicles with hard top 4 Remove the front subframe brace Remove the bolts All vehicles 5 Lower the vehicle SECTION 502 00 Frame and Body Mounting 2003 Mustang Workshop Manual Special Tool s Support Bar Engine 303 290 A Lifting Bra...

Page 4135: ...6 Install the special tool 7 Install the special tool 8 Raise and support the vehicle 9 Remove the two engine mount nuts 10 Lower the vehicle 11 Using the special tool raise and support the engine ...

Page 4136: ...12 Raise the vehicle 13 Support the front subframe 14 Remove the four front subframe lower bolts 15 Remove the four front subframe upper bolts 16 NOTE Two technicians are needed to carry out this step ...

Page 4137: ...Lower and remove the front subframe ...

Page 4138: ...r to Section 204 01 Vehicles with convertible top 3 Remove the front subframe support For additional information refer to Subframe Support Convertible in this section Vehicles with hard top 4 Remove the front subframe brace Remove the bolts All vehicles 5 Lower the vehicle SECTION 502 00 Frame and Body Mounting 2003 Mustang Workshop Manual Special Tool s 3 Bar Engine Support Kit 303 F072 Lifting B...

Page 4139: ...6 Install the special tool 7 Install the special tool 8 Raise and support the vehicle 9 Remove the two engine mount nuts 10 Lower the vehicle 11 Using the special tool raise and support the engine ...

Page 4140: ...12 Raise the vehicle 13 Support the front subframe 14 Remove the four front subframe lower bolts 15 Remove the four front subframe upper bolts 16 NOTE Two technicians are needed to carry out this step ...

Page 4141: ...Lower and remove the front subframe 17 To install reverse the removal procedure ...

Page 4142: ...ecomes necessary Torque values must be used as specified during reassembly 1 Remove the rear coil springs For additional information refer to Section 204 02 2 Using the special tool raise the rear subframe 3 Remove and discard the rear subframe front bolts 4 Using the special tool lower and remove the rear subframe 5 NOTE Discard the old bolts and nuts Do not reuse install new bolts and nuts To in...

Page 4143: ......

Page 4144: ...to Section 100 02 2 Support the front subframe support 3 Remove the RH front subframe support bolts 4 Remove the LH front subframe support bolts 5 Remove the front subframe support Remove the bolts and lower the front subframe support 6 To install reverse the removal procedure SECTION 502 00 Frame and Body Mounting 2003 Mustang Workshop Manual ...

Page 4145: ......

Page 4146: ...n anti lock brake system may be included in BRAKES and WIRING DIAGRAMS for the specific manufacturer WIRING DIAGRAMS contains all wiring diagrams not included in STARTING CHARGING SYSTEMS and ACCESSORIES EQUIPMENT This includes Data Link Connectors Ground Distribution Power Distribution Engine Performance Electric Cooling Fans Anti Lock Brakes Electronic Suspension and Electronic Steering wiring d...

Page 4147: ...Brown BRN BN Clear CLR CR Dark Blue DK BLU DK BU Dark Green DK GRN DK GN Green GRN GN Gray GRY GY Light Blue LT BLU LT BU Light Green LT GRN LT GN Orange ORG OG Pink PNK PK Purple PPL PL Red RED RD Tan TAN TN Violet VIO VI White WHT WT Yellow YEL YL ...

Page 4148: ...tration depicts standardized ground numbers and locations to be used in conjunction with wiring diagrams applying to 2001 and prior model years only See Fig 2 Wiring diagrams applying to newer model years depict manufacturer specified ground numbers and locations Do not utilize the illustration with 2002 and newer ...

Page 4149: ...to locate a component in a wiring diagram and you don t know the specific system where it is located use this handy component locator to find the system wiring diagram in which the component is located Then go to that system and locate the component within the wiring diagram model year wiring diagrams ...

Page 4150: ...utch Relay Engine Performance A C Sensor Engine Performance A C Pressure Switch Engine Performance Adaptive Lamp Control Module Exterior Lights Air Bag s Air Bag Restraint System Air Bag Module Air Bag Restraint System Air Bag Sensor s Air Bag Restraint System Air Injection Pump Relay Engine Performance Air Temperature Sensor Overhead Console Alternator Generator Generators Regulators Anti Theft C...

Page 4151: ... Air Bag Restraint System Distributor Engine Performance Door Lock Actuators Power Door Locks Remote Keyless Entry Door Lock Relay s Power Door Locks Electrochromic Mirror Power Mirrors Electronic Level Control ELC Height Sensor Electronic Suspension Electronic Level Control ELC Module Electronic Suspension Engine Coolant Temperature ECT Sending Unit Analog Instrument Panels Engine Coolant Tempera...

Page 4152: ...gnition Module Engine Performance Ignition Switch Power Distribution Engine Performance Generators Regulators Starters Illuminated Entry Module Illumination Interior Lights Illumination Lights Illumination Interior Lights Impact Sensor Air Bag Restraint System Inertia Fuel Shutoff Switch Engine Performance Inhibit Relay Starters Instrument Cluster Analog Instrument Panels Intake Air Temperature IA...

Page 4153: ...s Power Door Locks Power Mirror Motors Power Mirrors Memory Systems Power Sliding Door Controller Power Sliding Side Door Power Seat Motors Power Seats Memory Systems Power Steering Pressure Switch Engine Performance Power Top Motor Power Convertible Top Power Top Relay s Power Convertible Top Powertrain Control Module Engine Performance Analog Instrument Panels Cruise Control Systems Data Link Co...

Page 4154: ...le Engine Performance Transmission Control Module TCM Engine Performance Starters Transmission Range Sensor Starters Back Up Lights Engine Performance Transmission Range Switch Back Up Lights Engine Performance Anti Theft System Turn Signal Flasher Exterior Lights Turn Signal Lights Exterior Lights Twilight Sentinel Switch Headlight Systems Daytime Running Lights Vapor Canister Leak Detection Pump...

Page 4155: ...2003 SYSTEM WIRING DIAGRAMS Ford Mustang AIR CONDITIONING 3 8L 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4156: ...Fig 1 3 8L Air Conditioning Circuit 4 6L 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4157: ...Fig 2 4 6L Air Conditioning Circuit ANTI LOCK BRAKES 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4158: ...Fig 3 Anti lock Brakes Circuit ANTI THEFT 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4159: ...Fig 4 Passive Anti theft Circuit BODY CONTROL MODULES 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4160: ...Fig 5 Body Control Modules Circuit COMPUTER DATA LINES 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4161: ...Fig 6 Computer Data Lines Circuit COOLING FAN 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4162: ...3 8L Fig 7 3 8L Cooling Fan Circuit 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4163: ...4 6L Fig 8 4 6L Cooling Fan Circuit 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4164: ...CRUISE CONTROL Fig 9 Cruise Control Circuit 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4165: ...DEFOGGERS Fig 10 Defoggers Circuit 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4166: ...ENGINE PERFORMANCE 3 8L 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4167: ...Fig 11 3 8L Engine Performance Circuit 1 of 3 Fig 12 3 8L Engine Performance Circuit 2 of 3 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4168: ...Fig 13 3 8L Engine Performance Circuit 3 of 3 4 6L DOHC 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4169: ...Fig 14 4 6L DOHC Engine Performance Circuit 1 of 3 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4170: ...Fig 15 4 6L DOHC Engine Performance Circuit 2 of 3 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4171: ...Fig 16 4 6L DOHC Engine Performance Circuit 3 of 3 4 6L SC 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4172: ...Fig 17 4 6L SC Engine Performance Circuit 1 of 3 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4173: ...Fig 18 4 6L SC Engine Performance Circuit 2 of 3 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4174: ...Fig 19 4 6L SC Engine Performance Circuit 3 of 3 4 6L SOHC 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4175: ...Fig 20 4 6L SOHC Engine Performance Circuit 1 of 3 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4176: ...Fig 21 4 6L SOHC Engine Performance Circuit 2 of 3 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4177: ...Fig 22 4 6L SOHC Engine Performance Circuit 3 of 3 EXTERIOR LIGHTS 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4178: ...Fig 23 Back up Lamps Circuit 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4179: ...Fig 24 Exterior Lamps Circuit GROUND DISTRIBUTION 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4180: ...Fig 25 Ground Distribution Circuit 1 of 2 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4181: ...Fig 26 Ground Distribution Circuit 2 of 2 HEADLIGHTS 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4182: ...Fig 27 Headlights Circuit HORN 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4183: ...Fig 28 Horn Circuit INSTRUMENT CLUSTER 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4184: ...Fig 29 Instrument Cluster Circuit INTERIOR LIGHTS 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4185: ...Fig 30 Courtesy Lamps Circuit 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4186: ...Fig 31 Instrument Illumination Circuit POWER DISTRIBUTION 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4187: ...Fig 32 Power Distribution Circuit 1 of 3 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4188: ...Fig 33 Power Distribution Circuit 2 of 3 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4189: ...Fig 34 Power Distribution Circuit 3 of 3 POWER DOOR LOCKS 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4190: ...Fig 35 Power Door Locks Circuit POWER MIRRORS 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4191: ...Fig 36 Power Mirrors Circuit POWER SEATS 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4192: ...Fig 37 Lumbar Circuit 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4193: ...Fig 38 Power Seat Circuit POWER TOP SUNROOF 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4194: ...Fig 39 Power Top Sunroof Circuit POWER WINDOWS 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4195: ...Fig 40 Power Windows Circuit Convertible 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4196: ...Fig 41 Power Windows Circuit Coupe RADIO 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4197: ...Fig 42 Base Radio Circuit 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4198: ...Fig 43 Premium Sound Radio Circuit Convertible W Mach 1000 Sound System 1 of 2 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4199: ...Fig 44 Premium Sound Radio Circuit Convertible W Mach 1000 Sound System 2 of 2 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4200: ...Fig 45 Premium Sound Radio Circuit Coupe W Mach 1000 Sound System 1 of 2 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4201: ...Fig 46 Premium Sound Radio Circuit Coupe W Mach 1000 Sound System 2 of 2 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4202: ...Fig 47 Premium Sound Radio Circuit W Mach 460 Sound System SHIFT INTERLOCK 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4203: ...Fig 48 Shift Interlock Circuit STARTING CHARGING 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4204: ...Fig 49 Charging Circuit 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4205: ...Fig 50 Starting Circuit SUPPLEMENTAL RESTRAINTS 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4206: ...Fig 51 Supplemental Restraints Circuit TRANSMISSION 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4207: ...Fig 52 A T Circuit TRUNK TAILGATE FUEL DOOR 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4208: ...Fig 53 Trunk Tailgate Fuel Door Circuit WARNING SYSTEMS 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4209: ...Fig 54 Warning Systems Circuit WIPER WASHER 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4210: ...Fig 55 Wiper Washer Circuit 2003 Ford Mustang 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4211: ...WIRING DIAGRAMS For information on using these wiring diagrams see USING SYSTEM WIRING DIAGRAMS article AIR CONDITIONING 3 8L 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4212: ...Fig 1 3 8L Air Conditioning Circuit 4 6L 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4213: ...Fig 2 4 6L Air Conditioning Circuit ANTI LOCK BRAKES 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4214: ...Fig 3 Anti lock Brakes Circuit ANTI THEFT 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4215: ...Fig 4 Passive Anti theft Circuit BODY CONTROL MODULES 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4216: ...Fig 5 Body Control Modules Circuit COMPUTER DATA LINES 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4217: ...Fig 6 Computer Data Lines Circuit COOLING FAN 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4218: ...3 8L Fig 7 3 8L Cooling Fan Circuit 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4219: ...4 6L Fig 8 4 6L Cooling Fan Circuit 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4220: ...CRUISE CONTROL Fig 9 Cruise Control Circuit 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4221: ...DEFOGGERS Fig 10 Defoggers Circuit 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4222: ...ENGINE PERFORMANCE 3 8L 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4223: ...Fig 11 3 8L Engine Performance Circuit 1 of 3 Fig 12 3 8L Engine Performance Circuit 2 of 3 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4224: ...Fig 13 3 8L Engine Performance Circuit 3 of 3 4 6L DOHC 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4225: ...Fig 14 4 6L DOHC Engine Performance Circuit 1 of 3 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4226: ...Fig 15 4 6L DOHC Engine Performance Circuit 2 of 3 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4227: ...Fig 16 4 6L DOHC Engine Performance Circuit 3 of 3 4 6L SC 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4228: ...Fig 17 4 6L SC Engine Performance Circuit 1 of 3 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4229: ...Fig 18 4 6L SC Engine Performance Circuit 2 of 3 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4230: ...Fig 19 4 6L SC Engine Performance Circuit 3 of 3 4 6L SOHC 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4231: ...Fig 20 4 6L SOHC Engine Performance Circuit 1 of 3 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4232: ...Fig 21 4 6L SOHC Engine Performance Circuit 2 of 3 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4233: ...Fig 22 4 6L SOHC Engine Performance Circuit 3 of 3 EXTERIOR LIGHTS 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4234: ...Fig 23 Back up Lamps Circuit 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4235: ...Fig 24 Exterior Lamps Circuit GROUND DISTRIBUTION 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4236: ...Fig 25 Ground Distribution Circuit 1 of 2 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4237: ...Fig 26 Ground Distribution Circuit 2 of 2 HEADLIGHTS 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4238: ...Fig 27 Headlights Circuit HORN 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4239: ...Fig 28 Horn Circuit INSTRUMENT CLUSTER 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4240: ...Fig 29 Instrument Cluster Circuit INTERIOR LIGHTS 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4241: ...Fig 30 Courtesy Lamps Circuit 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4242: ...Fig 31 Instrument Illumination Circuit POWER DISTRIBUTION 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4243: ...Fig 32 Power Distribution Circuit 1 of 3 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4244: ...Fig 33 Power Distribution Circuit 2 of 3 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4245: ...Fig 34 Power Distribution Circuit 3 of 3 POWER DOOR LOCKS 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4246: ...Fig 35 Power Door Locks Circuit POWER MIRRORS 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4247: ...Fig 36 Power Mirrors Circuit POWER SEATS 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4248: ...Fig 37 Lumbar Circuit 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4249: ...Fig 38 Power Seat Circuit POWER TOP SUNROOF 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4250: ...Fig 39 Power Top Sunroof Circuit POWER WINDOWS 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4251: ...Fig 40 Power Windows Circuit Convertible 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4252: ...Fig 41 Power Windows Circuit Coupe RADIO 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4253: ...Fig 42 Base Radio Circuit 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4254: ...Fig 43 Premium Sound Radio Circuit Convertible W Mach 1000 Sound System 1 of 2 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4255: ...Fig 44 Premium Sound Radio Circuit Convertible W Mach 1000 Sound System 2 of 2 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4256: ...Fig 45 Premium Sound Radio Circuit Coupe W Mach 1000 Sound System 1 of 2 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4257: ...Fig 46 Premium Sound Radio Circuit Coupe W Mach 1000 Sound System 2 of 2 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4258: ...Fig 47 Premium Sound Radio Circuit W Mach 460 Sound System SHIFT INTERLOCK 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4259: ...Fig 48 Shift Interlock Circuit STARTING CHARGING 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4260: ...Fig 49 Charging Circuit 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4261: ...Fig 50 Starting Circuit SUPPLEMENTAL RESTRAINTS 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4262: ...Fig 51 Supplemental Restraints Circuit TRANSMISSION 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4263: ...Fig 52 A T Circuit TRUNK TAILGATE FUEL DOOR 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4264: ...Fig 53 Trunk Tailgate Fuel Door Circuit WARNING SYSTEMS 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4265: ...Fig 54 Warning Systems Circuit WIPER WASHER 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4266: ...Fig 55 Wiper Washer Circuit 2003 Ford Mustang GT 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4267: ...ING DIAGRAMS For information on using these wiring diagrams see USING SYSTEM WIRING DIAGRAMS article AIR CONDITIONING 3 8L 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4268: ...Fig 1 3 8L Air Conditioning Circuit 4 6L 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4269: ...Fig 2 4 6L Air Conditioning Circuit ANTI LOCK BRAKES 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4270: ...Fig 3 Anti lock Brakes Circuit ANTI THEFT 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4271: ...Fig 4 Passive Anti theft Circuit BODY CONTROL MODULES 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4272: ...Fig 5 Body Control Modules Circuit COMPUTER DATA LINES 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4273: ...Fig 6 Computer Data Lines Circuit COOLING FAN 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4274: ...3 8L Fig 7 3 8L Cooling Fan Circuit 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4275: ...4 6L Fig 8 4 6L Cooling Fan Circuit 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4276: ...CRUISE CONTROL Fig 9 Cruise Control Circuit 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4277: ...DEFOGGERS Fig 10 Defoggers Circuit 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4278: ...ENGINE PERFORMANCE 3 8L 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4279: ...Fig 11 3 8L Engine Performance Circuit 1 of 3 Fig 12 3 8L Engine Performance Circuit 2 of 3 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4280: ...Fig 13 3 8L Engine Performance Circuit 3 of 3 4 6L DOHC 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4281: ...Fig 14 4 6L DOHC Engine Performance Circuit 1 of 3 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4282: ...Fig 15 4 6L DOHC Engine Performance Circuit 2 of 3 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4283: ...Fig 16 4 6L DOHC Engine Performance Circuit 3 of 3 4 6L SC 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4284: ...Fig 17 4 6L SC Engine Performance Circuit 1 of 3 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4285: ...Fig 18 4 6L SC Engine Performance Circuit 2 of 3 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4286: ...Fig 19 4 6L SC Engine Performance Circuit 3 of 3 4 6L SOHC 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4287: ...Fig 20 4 6L SOHC Engine Performance Circuit 1 of 3 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4288: ...Fig 21 4 6L SOHC Engine Performance Circuit 2 of 3 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4289: ...Fig 22 4 6L SOHC Engine Performance Circuit 3 of 3 EXTERIOR LIGHTS 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4290: ...Fig 23 Back up Lamps Circuit 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4291: ...Fig 24 Exterior Lamps Circuit GROUND DISTRIBUTION 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4292: ...Fig 25 Ground Distribution Circuit 1 of 2 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4293: ...Fig 26 Ground Distribution Circuit 2 of 2 HEADLIGHTS 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4294: ...Fig 27 Headlights Circuit HORN 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4295: ...Fig 28 Horn Circuit INSTRUMENT CLUSTER 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4296: ...Fig 29 Instrument Cluster Circuit INTERIOR LIGHTS 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4297: ...Fig 30 Courtesy Lamps Circuit 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4298: ...Fig 31 Instrument Illumination Circuit POWER DISTRIBUTION 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4299: ...Fig 32 Power Distribution Circuit 1 of 3 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4300: ...Fig 33 Power Distribution Circuit 2 of 3 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4301: ...Fig 34 Power Distribution Circuit 3 of 3 POWER DOOR LOCKS 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4302: ...Fig 35 Power Door Locks Circuit POWER MIRRORS 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4303: ...Fig 36 Power Mirrors Circuit POWER SEATS 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4304: ...Fig 37 Lumbar Circuit 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4305: ...Fig 38 Power Seat Circuit POWER TOP SUNROOF 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4306: ...Fig 39 Power Top Sunroof Circuit POWER WINDOWS 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4307: ...Fig 40 Power Windows Circuit Convertible 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4308: ...Fig 41 Power Windows Circuit Coupe RADIO 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4309: ...Fig 42 Base Radio Circuit 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4310: ...Fig 43 Premium Sound Radio Circuit Convertible W Mach 1000 Sound System 1 of 2 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4311: ...Fig 44 Premium Sound Radio Circuit Convertible W Mach 1000 Sound System 2 of 2 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4312: ...Fig 45 Premium Sound Radio Circuit Coupe W Mach 1000 Sound System 1 of 2 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4313: ...Fig 46 Premium Sound Radio Circuit Coupe W Mach 1000 Sound System 2 of 2 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4314: ...Fig 47 Premium Sound Radio Circuit W Mach 460 Sound System SHIFT INTERLOCK 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4315: ...Fig 48 Shift Interlock Circuit STARTING CHARGING 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4316: ...Fig 49 Charging Circuit 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4317: ...Fig 50 Starting Circuit SUPPLEMENTAL RESTRAINTS 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4318: ...Fig 51 Supplemental Restraints Circuit TRANSMISSION 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4319: ...Fig 52 A T Circuit TRUNK TAILGATE FUEL DOOR 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4320: ...Fig 53 Trunk Tailgate Fuel Door Circuit WARNING SYSTEMS 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4321: ...Fig 54 Warning Systems Circuit WIPER WASHER 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4322: ...Fig 55 Wiper Washer Circuit 2003 Ford Mustang Cobra 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4323: ...NG DIAGRAMS For information on using these wiring diagrams see USING SYSTEM WIRING DIAGRAMS article AIR CONDITIONING 3 8L 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4324: ...Fig 1 3 8L Air Conditioning Circuit 4 6L 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4325: ...Fig 2 4 6L Air Conditioning Circuit ANTI LOCK BRAKES 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4326: ...Fig 3 Anti lock Brakes Circuit ANTI THEFT 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4327: ...Fig 4 Passive Anti theft Circuit BODY CONTROL MODULES 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4328: ...Fig 5 Body Control Modules Circuit COMPUTER DATA LINES 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4329: ...Fig 6 Computer Data Lines Circuit COOLING FAN 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4330: ...3 8L Fig 7 3 8L Cooling Fan Circuit 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4331: ...4 6L Fig 8 4 6L Cooling Fan Circuit 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4332: ...CRUISE CONTROL Fig 9 Cruise Control Circuit 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4333: ...DEFOGGERS Fig 10 Defoggers Circuit 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4334: ...ENGINE PERFORMANCE 3 8L 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4335: ...Fig 11 3 8L Engine Performance Circuit 1 of 3 Fig 12 3 8L Engine Performance Circuit 2 of 3 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4336: ...Fig 13 3 8L Engine Performance Circuit 3 of 3 4 6L DOHC 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4337: ...Fig 14 4 6L DOHC Engine Performance Circuit 1 of 3 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4338: ...Fig 15 4 6L DOHC Engine Performance Circuit 2 of 3 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4339: ...Fig 16 4 6L DOHC Engine Performance Circuit 3 of 3 4 6L SC 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4340: ...Fig 17 4 6L SC Engine Performance Circuit 1 of 3 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4341: ...Fig 18 4 6L SC Engine Performance Circuit 2 of 3 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4342: ...Fig 19 4 6L SC Engine Performance Circuit 3 of 3 4 6L SOHC 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4343: ...Fig 20 4 6L SOHC Engine Performance Circuit 1 of 3 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4344: ...Fig 21 4 6L SOHC Engine Performance Circuit 2 of 3 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4345: ...Fig 22 4 6L SOHC Engine Performance Circuit 3 of 3 EXTERIOR LIGHTS 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4346: ...Fig 23 Back up Lamps Circuit 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4347: ...Fig 24 Exterior Lamps Circuit GROUND DISTRIBUTION 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4348: ...Fig 25 Ground Distribution Circuit 1 of 2 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4349: ...Fig 26 Ground Distribution Circuit 2 of 2 HEADLIGHTS 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4350: ...Fig 27 Headlights Circuit HORN 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4351: ...Fig 28 Horn Circuit INSTRUMENT CLUSTER 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4352: ...Fig 29 Instrument Cluster Circuit INTERIOR LIGHTS 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4353: ...Fig 30 Courtesy Lamps Circuit 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4354: ...Fig 31 Instrument Illumination Circuit POWER DISTRIBUTION 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4355: ...Fig 32 Power Distribution Circuit 1 of 3 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4356: ...Fig 33 Power Distribution Circuit 2 of 3 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4357: ...Fig 34 Power Distribution Circuit 3 of 3 POWER DOOR LOCKS 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4358: ...Fig 35 Power Door Locks Circuit POWER MIRRORS 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4359: ...Fig 36 Power Mirrors Circuit POWER SEATS 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4360: ...Fig 37 Lumbar Circuit 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4361: ...Fig 38 Power Seat Circuit POWER TOP SUNROOF 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4362: ...Fig 39 Power Top Sunroof Circuit POWER WINDOWS 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4363: ...Fig 40 Power Windows Circuit Convertible 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4364: ...Fig 41 Power Windows Circuit Coupe RADIO 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4365: ...Fig 42 Base Radio Circuit 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4366: ...Fig 43 Premium Sound Radio Circuit Convertible W Mach 1000 Sound System 1 of 2 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4367: ...Fig 44 Premium Sound Radio Circuit Convertible W Mach 1000 Sound System 2 of 2 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4368: ...Fig 45 Premium Sound Radio Circuit Coupe W Mach 1000 Sound System 1 of 2 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4369: ...Fig 46 Premium Sound Radio Circuit Coupe W Mach 1000 Sound System 2 of 2 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4370: ...Fig 47 Premium Sound Radio Circuit W Mach 460 Sound System SHIFT INTERLOCK 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4371: ...Fig 48 Shift Interlock Circuit STARTING CHARGING 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4372: ...Fig 49 Charging Circuit 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4373: ...Fig 50 Starting Circuit SUPPLEMENTAL RESTRAINTS 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4374: ...Fig 51 Supplemental Restraints Circuit TRANSMISSION 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4375: ...Fig 52 A T Circuit TRUNK TAILGATE FUEL DOOR 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4376: ...Fig 53 Trunk Tailgate Fuel Door Circuit WARNING SYSTEMS 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4377: ...Fig 54 Warning Systems Circuit WIPER WASHER 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

Page 4378: ...Fig 55 Wiper Washer Circuit 2003 Ford Mustang Mach 1 2003 SYSTEM WIRING DIAGRAMS Ford Mustang ...

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