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Ford 2003 Mustang Workshop Manual

Ford 2003 Mustang Workshop Manual

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SECTION 100-01: Identification Codes

DESCRIPTION AND OPERATION

Identification Codes

Vehicle Identification Number (VIN) Locator

The vehicle identification number (VIN) is a seventeen-digit alphanumeric 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.

Item

Description

1

World manufacturer identifier (WMI)

2

Restraint type code

3

Line, series, body type (passenger car)

4

Engine code

2003 Mustang Workshop Manual

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Page 1: Identification Codes
SECTION 100-01: Identification Codes 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Identification Codes Vehicle Identification Number (VIN) Locator The vehicle identification number (VIN) is a seventeen-digit alphanumeric 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.
Page 2 Vehicle Identification Number World Manufacturer Identifier (WMI) The first three vehicle identification number (VIN) positions are the world manufacturer identifier (WMI). 1FA — Ford, USA, passenger car Restraint Type Code The fourth VIN position is the vehicle restraint system type code.
Page 3 Positions 5 through 7 indicate vehicle line, series and body type. P40 — Two-door coupe P42 — Two-door coupe, GT (Mach One available in GT Coupe only) P44 — Two-door convertible P45 — Two-door convertible, GT P48 — Two-door coupe, Cobra P49 —...
Page 4 The ninth VIN position is a government 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 —...
Page 5 The last six VIN positions are the production sequence number. This number is also used as the vehicle serial and warranty number. 100001-599999 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.
Page 6: Paint Codes
Item Description Exterior paint color code Region code Special order code (DSO — domestic special order FSO — foreign special order PTO — paint, tire option special order) Brake type code Interior trim code Tape/paint stripe code Radio type code Axle ratio code Transmission code 10 Spring code...
Page 7 The first set of paint code letters/numbers listed indicate the vehicle primary body color. The second set of paint code letters/numbers listed (if applicable) indicate a two-tone or accent body color. B7 — Zinc Yellow (clear coat) CX — Dark Shadow Gray Metallic D3 —...
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 The interior trim codes are listed below. The first letter/number is for the interior fabric. The second letter is for the interior color. 9 — Quantum/Rhodes cloth (base coupe) A — Link weave cloth (Mach One) M — Nudo Leather (Cobra) T —...
Page 10 The radio type codes are: 2 — Premium 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 The axle ratio is: X5 — 3.8L, non-ABS, 3.27 ratio Z5 — 3.8L, ABS, 3.27 ratio ME — 4.6L, Mach 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) —...
Page 12 The spring code portion of the vehicle certification (VC) label identifies 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 —...
Page 13 On Line Automotive Service Information System (OASIS). For the current model year, Ford Motor Company is using three different protocols which describe powertrain base calibration. These protocols are designed to provide worldwide standardization for vehicle calibration.
Page 14 Design level (design level assigned to the engine) Protocol 3 Item Description Model year (model year in which calibration strategy was first introduced) Vehicle code Transmission code Unique calibration (designates different hardware to similar vehicles). Example: tires, drive ratios, etc. Fleet code (describes fleet to which the vehicle belongs).
Page 15 These two characters are chosen by the analyst to provide easily identifiable information unique to each calibration. For example, using the number 2 to denote a two-valve engine versus using the number 4 to denote a four-valve engine. Fleet Code 1 —...
Page 16 91-99 — Hardware certification levels 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 SECTION 100-02: Jacking and Lifting 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Jacking WARNING: Never run the engine with one wheel off the ground, such as when changing a tire. The wheel still on the ground could cause the vehicle to move.
Page 18 To lift the rear or either side of the rear end, position the floor jack under the rear lift points.
Page 19 SECTION 100-02: Jacking and Lifting 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Lifting CAUTION: Do not allow the lift adapters to contact the steering linkage, suspension arms, stabilizer arms, or to compress the lower suspension arm stabilizer bar insulator (5493).
Page 20 CAUTION: Do not position lift pads under the No. 3 crossmember. CAUTION: Do not lift vehicle on rocker panel pinch flange or convertible cross brace. Body damage may occur. NOTE: Adapters may be necessary to clear vehicle components to lift the vehicle safely. The adapters must be placed at the four designated contact points.
Page 22 General Maintenance Information NOTE: This is a generic maintenance schedule for all Ford, Lincoln and Mercury vehicles. There may be items listed that do not apply to all vehicles. The Normal Schedule applies to operation of the vehicle under typical, everyday driving conditions.
Page 23 Change engine oil and install a new oil filter, lube front lower control arm and steering linkage ball joints with zerk fittings (if equipped) every 4,800 km (3,000 miles) or 3 months. Inspect brake system and check battery electrolyte level (Patrol cars) every 8,000 km (5,000 miles).
Page 24 Engine oil fluid level. Windshield washer solvent fluid level. Check and drain fuel/water separator. Six Month Checks Check each of the following items at least every six months: Lap/shoulder belts and seat latches for wear and function. Spare tire air pressure. Power steering fluid level.
Page 25 If equipped, inspect automatic transmission fluid level with 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 steering linkage, suspension and (if equipped) driveshaft and ball joints. Rotate tires and inspect for wear.
Page 26 Change engine oil and install a new oil filter. Inspect tires for wear. Rotation recommended for optimal tire life. 64,000 Km (40,000 Miles) Change engine oil and install a new oil filter. Inspect tires for wear. Rotation recommended for optimal tire life. 72,000 Km (45,000 Miles) Change engine oil and install a new oil filter.
Page 27 equipped. If equipped, install new climate controlled seat filters (Navigator, Lincoln LS and Aviator). ADDITIONAL INFORMATION: If vehicle is registered in California, the California Air Resources Board (CARB) has determined that failure to install a new fuel filter at this interval will not nullify the emission warranty or limit recall liability prior to completion of the vehicle's useful life.
Page 28 Inspect wheel ends for end play and noise. Inspect engine cooling 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.
Page 29 Change engine oil and install a new oil filter. Inspect tires for wear. Rotation recommended for optimal tire life. 184,000 Km (115,000 Miles) Change engine oil and install a new oil filter. Inspect tires for wear. Rotation recommended for optimal tire life. 192,000 Km (120,000 Miles) Change engine oil and install a new oil filter.
Page 30 If equipped, inspect automatic transmission fluid level with 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 steering linkage, suspension and (if equipped) driveshaft and ball joints. Rotate tires and inspect for wear.
Page 31 Rear axles and power take off (PTO) units containing synthetic lubricant and light duty trucks equipped with Ford-design axles are lubricated for life. These lubricants are not to be checked or changed unless service is required, or if a leak is suspected, or the axle assembly has been submerged in water.
Page 33 SECTION 100-04: Noise, Vibration and Harshness 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer.
Page 34 Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds.
Page 35 The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle.
Page 36 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes.
Page 37 starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the driveshaft, and the rear axle pinion centerline.
Page 38 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center, causing excessive motion.
Page 39 A mid-range frequency (200-800 Hz) noise between drumming and whine. Also described as a hum. Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration.
Page 40: Road Test
Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa.
Page 41 Lateral runout means measuring the movement or "wobble" of a wheel or tire at the sidewall. Radial runout means measuring the out-of-round at the tread surface. Rustling Intermittent sound of varying frequency (100-2000 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement.
Page 42: Wind Noise
A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). The acronym for total indicated runout is TIR. Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off.
Page 43 The acronym for wide open throttle is WOT. Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes.
Page 44 Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Place the vibration sensor on or near the suspect area outside the vehicle. e. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading.
Page 45 and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak.
Page 46 Index Card Place an index card or a piece of paper between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the index card or 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.
Page 48 SECTION 100-04: Noise, Vibration and Harshness 2003 Mustang Workshop Manual DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Special Tool(s) ChassisEAR 107-R2102 or equivalent Electronic Vibration Analyzer 100-F027 (014-00344) or equivalent EngineEAR 107-R2100 or equivalent Ultrasonic Leak Detector 134-R0135 or equivalent To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material.
Page 51 Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test 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.
Page 52 Did any abnormal occurrence coincide with or proceed its appearance? Use the information gained from the customer to accurately begin the diagnostic process. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
Page 53 NOTE: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test, take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears.
Page 54 Neutral Coast Down Speed Test To carry out this test, proceed as follows: Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. The concern is vehicle speed-related if duplicated while carrying out this test.
Page 55 Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. Proceed as necessary. Neutral Engine Run-Up (NERU) Test To carry out this test, proceed as follows: Install a tachometer.
Page 56 NOTE: A serpentine drive belt decreases the usefulness of this test. In these cases, use a vibration analyzer, such as the VA, to pinpoint accessory vibrations. An electronic listening device, such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts.
Page 57 After determining the "system", use the diagnostic tools to identify the worn or damaged "components". After identifying the "components", try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition, proceed to NVH Condition and Symptom Categories.
Page 58 Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart — Driveline Noise/Vibration A low-pitched noise (drumming). GO to Symptom Chart — Engine Noise/Vibration Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration.
Page 59 A wobble or shudder. GO to Symptom Chart — Tire Noise/Vibration 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart — Suspension Noise/Vibration Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart —...
Page 60 No contact with side ADJUST the door glass. glass. No contact with glass ADJUST the belt line seal runs at both ends of or ADD foam at the seal belt line seal. ends. Belt line seal damaged. INSTALL a new seal. Air leak at outer Belt line seal installed ADJUST the seal.
Page 61 glass Air traveling up INSTALL foam rope the windshield molding full length of the A-pillar. along A-pillar. Windshield/backlite REINSTALL the misaligned or not windshield/backlite. installed correctly. Rear hood seal at base REALIGN or INSTALL a of windshield new seal as necessary. misaligned/damaged.
Page 62 Body panel misaligned REALIGN the appropriate (exposed edge). body panel. Hood misaligned (front CHECK hood gaps and fit. margin). ADJUST the hood as necessary. Front grille edge noise. APPLY foam in the hollow areas behind the louvers. Wind noise Grille relationship to ADJUST the grille created by grille leading edge on hood.
Page 63 with header. Convertible top Vinyl top contacting Working from front to flapping with the interior headliner. back, INSTALL a 6.35 mm top up (0.25 in) foam sheet between the headliner and the vinyl top at the suspected area. Allow a clearance of 50 mm (2 in) - 75 mm (3 in) away from the roof bows and the side...
Page 64 occurs on first pads. Caused by humidity and (morning) brake low disc brake pad application temperature. Squealing noise—a Disc brake pads INSTALL new disc brake continuous squeal or linings worn pads. REFER to Section below minimum 206-03 for front disc brake thickness.
Page 65 INSTALL a new ring and pinion as necessary. REFER to Section 205-02A for Ford 7.5 rear axles or Section 205-02B for Ford 8.8 integral axles. Damaged or CHECK for abnormal worn differential bearing play or roughness.
Page 66 components as necessary. Broken INSPECT the powertrain powertrain mounts. INSTALL new mounts. mounts as necessary. REFER to Section 303-01A for 3.8L engines or Section 303-01B for 4.6L (2V) engines. Idle speed too CHECK for the correct idle high. speed. Driveline clunk— Worn or galled CLEAN and INSPECT the occurs as the vehicle...
Page 67 INSTALL a new differential as necessary. REFER to Section 205-02A for Ford 7.5 rear axles or Section 205-02B for Ford 8.8 integral axles. Buzz—buzzing noise Damaged or CHECK for abnormal tire is the same at cruise worn tires. wear or damage. INSTALL a or coast/deceleration new tire as necessary.
Page 68 Ring and Pinion component test in this section. 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. Chuckle—heard at Incorrect ring CHECK the ring and pinion coast/deceleration.
Page 69 Loose rear INSPECT the U-bolts. spring U-bolts. TIGHTEN the U-bolt nuts to specification. REFER to Section 204-02 Incorrect or high CHECK vehicle ride height CV joint is within limits. REPAIR as operating angle. necessary. REFER to Section 206-00 Damaged or CHECK for a loose stabilizer worn front bar, damaged or loose...
Page 70 CARRY OUT a driveline vibration test. REFER to Section 205-00 . REPAIR as necessary. Binding or CLEAN and INSPECT the damaged splines of the slip-yoke, splines on the driveshaft and coupling driveshaft slip- shaft for wear or damage. yoke. INSTALL a new slip-yoke or driveshaft assembly as necessary.
Page 71 noise—normally Powertrain/Drivetrain accompanied by Mount Neutralizing in this vibration section. Damaged or INSPECT the exhaust misaligned exhaust system for loose or broken system. clamps and brackets. CARRY OUT Exhaust System Neutralizing in this section. Whistling noise— Air intake system. CHECK the air intake normally ducts, air cleaner, throttle accompanied...
Page 72 described as injector connector until the piston slap. Noise noise goes away. CARRY is most OUT a cylinder bore noticeable when clearance to piston check. engine is cold INSTALL a new piston. with light to REFER to Section 303-01A medium for 3.8L engines or Section acceleration.
Page 73 Generator electrical CARRY OUT generator field or bearings. load test. REPAIR or INSTALL a new generator as necessary. REFER to Section 414-02 Drone type noise Exhaust system. CARRY OUT the Exhaust System Neutralizing in this section. REPAIR as necessary. A/C compressor. CHECK for noise with vehicle at constant speeds.
Page 74 Excessive runout of CARRY OUT a valve seat valve seats on the runout test. INSPECT the valve face. valve face and seat. INSTALL new valves as necessary. REFER to Section 303-01A for 3.8L engines or Section 303-01B for 4.6L (2V) engines. Rattling noise—...
Page 75 as necessary. Accelerator pedal Throttle cable loose INSPECT the throttle cable. vibration—felt or misrouted. REPAIR as necessary. through the pedal REFER to Section 310-02 as a buzz Engine Combustion CHECK the ignition system. vibration—mostly instability. INSTALL new components at coast/neutral as necessary.
Page 76 (+40°F) or colder at between ball first start of the day bearings and bearing race. Power steering moan High fluid Go To Pinpoint Test D — occurs at high idle viscosity, or and possibly at idle plugged during the first cold reservoir screen start of the day in in power...
Page 77 port. DISCARD the leaking parts, and INSTALL a new component. Vehicles with a Acceptable condition. Some plastic intake plastic manifolds exhibit this manifold. noise, which is the effect of the plastic manifold. Automatic Incorrect CHECK for correct driveline transmission buzz or driveline angles.
Page 78 high idle during the lifter/lash first cold start of the adjuster). A continuous, speed- Piston noise or Go To Pinpoint Test G dependent rattle from valvetrain noise the engine — occurs (bled down during idle or high idle lifter/lash during the first cold adjuster).
Page 79 closing/opening the window Squeak—heard Exhaust shield CHECK the exhaust system. outside of vehicle rubbing against REPAIR as necessary. REFER when the chassis or Section 309-00 closing/opening exhaust pipe. the door Squeak—occurs Disc brake pads. Under certain conditions, with initial brake asbestos free pads can pedal application generate a squeak noise.
Page 80 misaligned. screws. REPAIR as necessary. Loose interior CARRY OUT a "touch test". component or ELIMINATE the noise by trim. pressing or pulling on interior trim and components. USE the Rotunda Squeak and Rattle Kit to isolate any rattling/squeaking components. Squeak or rattle— Damaged or INSPECT the upper and lower noise with a...
Page 81 REFILL as necessary. Power steering pump CHECK bolts, brackets brackets loose or and bracket alignment. misaligned. TIGHTEN bolts to specification. REPAIR or INSTALL new brackets as necessary. REFER to Section 211- Steering gear clunk Steering gear. INSPECT the steering — occurs only gear for loose mounting while cornering bolts.
Page 82 surfaces Yoke spring in the CHECK TSBs for steering gear. revised yoke spring for applicable vehicles. Accessory drive Loose or worn ADJUST or INSTALL a belt squeal/chirp— accessory drive belt. new accessory belt as when rotating the necessary. REFER to steering wheel Section 303-05 from stop to stop...
Page 83 end surface of the power steering pump rotor. Damaged or worn power steering pump rotor splines. A crack on the inner surface of the power steering pump cam. Interference between the power steering pump rotor and cam. Damaged or worn power steering pump rotor and pressure plates.
Page 84 Clunk—noise from the Loose front INSPECT for loose nuts front suspension, occurs struts or shocks. or bolts. TIGHTEN to in and out of turns specifications. REFER to Section 204-01 Clunk—noise from the Loose rear INSPECT for loose or rear suspension, occurs suspension damaged rear when shifting from...
Page 85 acceleration from a slow assembly and the rear suspension speed or stop mispositioned. for damage or wear. REPAIR as necessary. Incorrect or high CHECK vehicle ride CV joint height is within limits. operating angle. REPAIR as necessary. Damaged or CHECK for a loose worn front stabilizer bar, damaged suspension...
Page 86 Damaged or INSPECT the suspension worn suspension components for wear or components. damage. REPAIR as necessary. Loose wheel CHECK the wheel nuts. nuts. TIGHTEN to specification. REFER to Section 204- Damaged or SPIN the tire and CHECK uneven tire wear. for abnormal tire wear or damage.
Page 87 Symptom Chart—Transmission (Manual) and Transfer Case Noise/Vibration Condition Possible Sources Action Clutch rattling noise— Flywheel bolts, TIGHTEN the bolts to occurs with clutch clutch housing bolts specifications. CHECK engaged, noise or clutch pressure the bolts for damage. changes/disappears plate bolts loose. with clutch pedal depressed Clutch squeaking...
Page 88 Section 308-02 Grease or oil on the CHECK the input shaft clutch disc facing. seal and rear main oil seal. REPAIR as necessary. INSTALL a new clutch disc. REFER to Section 308- for T50D transmissions or Section 308-03B TR3650 transmissions. Clutch disc surface INSPECT the clutch glazed or damaged.
Page 89 REFER to Section 303- Excessive backlash CHECK the gear in gears backlash. ADJUST as necessary. REFER to Section 205-02A Ford 7.5 rear axles or Section 205-02B Ford 8.8 integral axles. Worn countershaft REPAIR as necessary. gears. REFER to Section 308-...
Page 90 Mismatched gear INSPECT the gear sets sets. for an uneven wear pattern on the face of the gear teeth. REPAIR as necessary. REFER Section 308-03A T50D transmissions or Section 308-03B TR3650 transmissions. Damaged or worn INSPECT the transmission transmission bearings. bearing.
Page 91 information, REFER to Section 205-00 REPAIR as necessary. Transmission Damaged or worn CHECK transmission rumble/growl—noise at transmission fluid for excessive all speeds in forward bearing or gears metal particles. gears, more (high mileage REPAIR as necessary. pronounced in a heavy vehicles).
Page 92 flange runout. Symptom Chart—Transmission (Automatic) Noise/Vibration Condition Possible Sources Action Rattle—occurs Damaged engine or CHECK the at idle or at transmission mounts. powertrain/drivetrain mounts light for damage. REPAIR or acceleration INSTALL new mounts as from a stop necessary. A loose front exhaust REPAIR or INSTALL a new pipe heat shield.
Page 93 CHECK for abnormal bearing pinion bearings. play or roughness. INSTALL new bearings as necessary. REFER to Section 205-02A for Ford 7.5 rear axles or Section 205-02B for Ford 8.8 integral axles. Worn or galled CLEAN and INSPECT the driveshaft slip yoke splines of the yoke.
Page 94 Bump—occurs Initial gear Acceptable condition. when shifting engagement. from PARK to a drive or reverse position. Similar to Clunk but with no sound Buzz or hiss Incorrect driveline CHECK for correct driveline angles. angles. REPAIR as necessary. REFER to Section 205-00 Worn or damaged Using a transmission tester,...
Page 95 condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. Reinstall all components after verifying system operation is normal.
Page 96 INSPECT the wheel bearings. ADJUST or REPAIR as necessary. TEST the system for normal operation. A6 CHECK THE FRONT SUSPENSION Check the front suspension for: GO to Broken or loose bolts. Damaged springs. Worn or damaged upper and lower control arm REPAIR or INSTALL bushings.
Page 97 CHECK for TSB for applicable vehicle. Is the ticking noise gone? REPAIR as necessary. TEST the system for normal operation. GO to B2 CHECK FOR TICKING NOISE AT THE FUEL INJECTOR Using an EngineEAR, listen at the fuel INSTALL a new fuel injector. REFER to injectors by placing a probe on each injector.
Page 98 operating correctly? INSTALL a new valve lifter/lash adjuster (s). TEST the system for normal operation. PINPOINT TEST C: ACCESSORY DRIVE BEARING HOOT Test Step Result / Action to Take C1 CHECK THE IDLER AND TENSIONER PULLEY BEARINGS Carry out the Vehicle Cold Soak INSTALL a new pulley/idler.
Page 99 Carry out the Vehicle Cold Soak Procedure TEST the fan for normal operation. If the in this section. fan tests normal, GO to . Otherwise, Key in START position. REPAIR as necessary. Assess the airflow. Raise the engine speed to 1500 rpm while listening for the moan to increase in Normal system operation.
Page 100 CONDUCT diagnosis of other suspect components. PINPOINT TEST G: ENGINE TICKING, KNOCKING OR CONTINUOUS RATTLE Test Step Result / Action to Take G1 CHECK FOR NOISE AT THE VALVE COVERS AND THE FRONT COVERS (OHC ENGINES) Carry out the Vehicle Cold Soak Procedure in REMOVE the appropriate cover and this section.
Page 101 REPAIR the steering WARNING: The electrical power to the air system. INSTALL new suspension system must be shut off prior to hoisting, components as necessary. jacking or towing an air suspension vehicle. This can TEST the system for normal be accomplished by turning off the air suspension operation.
Page 102 I1 ROAD TEST THE VEHICLE Test drive the vehicle. GO to NOTE: An assistant will be needed for this road test. During the road test, drive the vehicle over a rough road. Using ChassisEARs, determine from which The suspension system is area/component the noise is originating.
Page 103 Take J1 ROAD TEST THE VEHICLE NOTE: Wheel or tire vibrations felt in the steering wheel are most GO to likely related to the front wheel or tire. Vibration felt through the seat are most likely related to the rear wheel or tire. This may not always be true, but it can help to isolate the problem to the front The wheel and tires or rear of the vehicle.
Page 104 Are there signs of visual runout? J5 RADIAL RUNOUT CHECK ON THE TIRE Measure the radial runout of the wheel and tire assembly. A GO to typical specification for total radial runout is 0.045 inch. GO to Is the radial runout within specifications? J6 RADIAL RUNOUT CHECK ON THE WHEEL Measure the radial runout of the wheel.
Page 105 GO to Is the lateral runout within specifications? J9 LATERAL RUNOUT CHECK ON THE WHEEL Measure the lateral runout of the wheel. A typical specification for INSTALL a new tire. total radial runout is 1.14mm (0.045 inch. TEST the system for Is the lateral runout within specifications? normal operation.
Page 106 operation. K3 MEASURE THE LATERAL RUNOUT AND THE RADIAL RUNOUT OF THE FRONT WHEELS ON THE VEHICLE Measure the lateral runout and the radial runout of the front GO to wheels on the vehicle. Refer to Go To Pinpoint Test J Are the measurements within specifications? INSTALL new wheels as necessary and BALANCE...
Page 107 persists,GO to INSTALL a new wheel. CHECK the runout on the new wheel. If the new wheel is within limits, LOCATE and MARK the low spot. INSTALL the tire, matching the high spot on the tire with the low spot on the wheel. Is the runout within specifications? BALANCE the assembly.
Page 108 assemblies as necessary. appropriate workshop manual for the service procedures. TEST the system for Secure the brake drums (if so equipped), by installing wheel normal operation. hub bolt nuts, reversed. Carefully accelerate the drivetrain while checking for vibration. Is the vibration present? PINPOINT TEST L: CLUTCH VIBRATION Test Step Result / Action to Take...
Page 109 the system for normal operation. GO to L6 CHECK THE FLYWHEEL BOLTS Check for loose flywheel bolts. TIGHTEN the bolts to Are the bolts loose? specifications. REFER to Section 308-01 . TEST the system for normal operation. GO to L7 CHECK THE FLYWHEEL SURFACE Inspect the flywheel surface for wear or damage.
Page 110 GO to M4 INSPECT THE FRONT DRIVESHAFT NOTE: Verify that the driveshaft and pinion flange index marks REPAIR or INSTALL a are aligned. new driveshaft as Inspect the front driveshaft for missing weights, damage or necessary. TEST the undercoating. system for normal Inspect the U-joints and slip yoke for freedom of movement.
Page 111 Section 100-02 2. Drain the axle lubricant. Refer to Section 205-02A for Ford 7.5 rear axles or Section 205-02B Ford 8.8 integral axles. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to Section 205-02A for Ford 7.5 rear axles or...
Page 112 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the" heel" or "toe" of the differential ring gear. Item Description Heel 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained.
Page 113 Tooth contact pattern shown on the drive side of the gear teeth. The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear.
Page 114: Tire Wear Chart
Tooth 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 Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm, or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel.
Page 116 For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: Measure the diameter of the tire. Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart.
Page 118 SECTION 100-04: Noise, Vibration and Harshness 2003 Mustang Workshop Manual GENERAL PROCEDURES Brake Disc Machining Special Tool(s) Gauge, Clutch Housing 308-021 (T75L-4201-A) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Material Item Specification Metal Surface Cleaner WSE-M5B392- F4AZ-19A536-RA or equivalent...
Page 119 6. For vehicles with a two-piece hub and brake disc assembly: Match-mark before disassembly. Remove the brake disc. Clean the hub and brake disc mounting surfaces with metal surface cleaner. Using a die grinder with a mild abrasive (Scotch Brite® type), remove any rust or corrosion from the hub and brake disc mounting surfaces.
Page 121 SECTION 100-04: Noise, Vibration and Harshness 2003 Mustang Workshop Manual GENERAL PROCEDURES Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch.
Page 122 SECTION 100-04: Noise, Vibration and Harshness 2003 Mustang Workshop Manual GENERAL PROCEDURES Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area.
Page 124 SECTION 100-04: Noise, Vibration and Harshness 2003 Mustang Workshop Manual GENERAL PROCEDURES Wheel Bearing Check WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch.
Page 126 SECTION 204-00: Suspension System — General Information 2003 Mustang Workshop Manual SPECIFICATIONS Alignment Specifications Item Total/Split Front Caster 3.2° ± 0.75° 3.2° ± 0.75° 0° ± 0.75° Camber— GT and Base -0.50° ± 0.75° -0.50° ± 0.75° 0° ± 0.75°...
Page 127 Description Nm lb-ft Front suspension camber adjustment plate bolt Front suspension camber adjustment plate nuts 40 Rear camber adjustment nut Toe link jam nuts Tie-rod jam nuts...
Page 128 SECTION 204-00: Suspension System — General Information 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Wheel Alignment Angles Camber and toe are adjustable on the front suspension systems. Front camber is adjusted by moving the top of the strut and spring assembly. Rear camber is adjusted by means of eccentric cams on the rear upper arms.
Page 129 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 Item Description Ride height = B - A Measurement A Measurement B Rear Ride Height Measurement — GT and Base...
Page 131 Item Description Body reinforcement Ride height (shortest distance) Rear axle Wheel Track Item Part Number Description — Front track — Rear track Dogtracking Item Part Number Description — Vehicle centerline — Axle centerline — Thrust angle Dogtracking or thrust angle is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking.
Page 132 Shimmy Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface.
Page 134: Suspension System
SECTION 204-00: Suspension System — General Information 2003 Mustang Workshop Manual DIAGNOSIS AND TESTING Suspension System Inspection and Verification 1. Road test. Verify the customer's concern by performing a road test on a smooth road. 2. Inspect tires. Check the tire pressure with all normal loads in the vehicle and the tires cold. For additional information, refer to the vehicle certification (VC) label.
Page 135 Front wheel bearing(s) Loose or damaged front or rear suspension components Loose, damaged or missing suspension fastener(s) Damaged spring(s) Damaged or leaking strut and spring assemblies Damaged or leaking shock absorber(s) Worn or damaged suspension bushing(s) Loose, worn or damaged steering system components Damaged axle components 6.
Page 136 Excessive front or CHECK the wheel alignment. rear toe (rapid inner ADJUST as necessary. or outer edge wear). Excessive negative CHECK the wheel alignment. or positive camber ADJUST as necessary. (rapid inner or outer edge wear). Tires out of balance BALANCE tires.
Page 137 REFER to Section 204-04 Strut(s). INSTALL new strut(s) as necessary. REFER to Section 204-01 Shock absorber(s). INSTALL new shock absorber (s) as necessary. Loose front TIGHTEN to specification. stabilizer bar (5482) REFER to Section 204-01 or rear stabilizer Section 204-02 bar (5A772).
Page 138 Steering REFER to Section 211-00 components. Wheel alignment. CHECK wheel alignment. ADJUST as necessary (excessive total front toe out). Component Tests Ball Joint Inspection 1. Raise and support the vehicle. Refer to Section 100-02 2. Prior to performing any inspection of the ball joints, inspect the wheel bearings. 3.
Page 140 SECTION 204-00: Suspension System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Wheel Bearing Inspection 1. Raise the vehicle until the tire is off the floor. For additional information, refer to Section 100-02 2. NOTE: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly.
Page 141 SECTION 204-00: Suspension System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Camber and Caster Adjustment —Front All vehicles 1. Remove the rivet. Loosen the nuts and bolt. Vehicles requiring camber adjustment 2. Move the front suspension camber adjusting plate (3B391) to the required camber setting.
Page 142 5. Remove the nuts, bolt and the front suspension camber adjusting plate. 6. Raise the front end. Position the strut and spring assembly out of the way. For additional information, refer to Section 100-02 7. Cut slots perpendicular to the existing camber adjustment slots. Moving the top of the front shock absorber toward the rear of the vehicle will increase the caster reading for that side.
Page 143 10. Align the camber marks 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 145 SECTION 204-00: Suspension System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Camber Adjustment —Rear 1. Loosen the nut. 2. Rotate the bolt and the cam to the correct camber setting. 3. Tighten the nut while holding the bolt and the cam stationary.
Page 147 SECTION 204-00: Suspension System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Toe Adjustment —Front 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the straight forward position by attaching a rigid link from the steering wheel to the seat.
Page 148 7. Tighten the nuts. 8. Install the clamps. 9. Recheck the toe settings. Follow the manufacturer's instructions.
Page 150 SECTION 204-00: Suspension System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Toe Adjustment —Rear 1. Loosen the nuts. To prevent damage to the ball joints, hold the tie-rod ends while loosening the nuts. 2. Rotate the toe link to the correct toe setting.
Page 151 4. Recheck the toe settings. Follow the manufacturer's instructions.
Page 152 SECTION 204-01: Front Suspension 2003 Mustang Workshop Manual SPECIFICATIONS Torque Specifications Description Nm lb-ft lb-in Front shock absorber upper nut 100 74 — Front shock absorber-to-spindle nuts 200 148 — Shock absorber upper mount-to-body nuts 40 — Shock absorber upper mount-to-body bolt —...
Page 153 SECTION 204-01: Front Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Wheel Studs Removal 1. Remove the wheel hub (1104). For additional information, refer to Wheel Hub and Bearing this section. 2. Using a press, remove the wheel stud (1107) from the wheel hub.
Page 155 SECTION 204-01: Front Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Wheel Hub and Bearing Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary.
Page 156 Installation 1. NOTE: Use a new wheel hub retainer and hub cap grease seal. To install, reverse the removal procedure.
Page 157 SECTION 204-01: Front Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Arm —Lower Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary.
Page 158 6. Remove the front coil spring (5310). For additional information, 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 SECTION 204-01: Front Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Bar —Stabilizer Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary.
Page 160 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 162 SECTION 204-01: Front Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Link —Stabilizer Bar Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary.
Page 164 SECTION 204-01: Front Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Bushing —Stabilizer Bar Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary.
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 167 SECTION 204-01: Front Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Spindle Special Tool(s) Tie-Rod End Remover 211-001 (TOOL-3290-D) or Equivalent Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number or an equivalent part must be installed, if installation is necessary.
Page 168 6. Remove the front brake disc shield. 1. Remove the three shield rivets. 2. Remove the shield. 7. Remove the cotter pin and nut. Discard the cotter pin. CAUTION: Use care not to damage the tie-rod end dust boot. Using the special tool, disconnect the tie-rod end from the front wheel spindle. CAUTION: To prevent damage to the front suspension lower arm (3078), do not remove the nut from the ball joint (3050) at this time.
Page 169 10. Support the front suspension lower arm with a jack stand. 11. Remove the nut and the ABS sensor wire bracket. WARNING: All vehicles are equipped with gas pressurized shock absorbers which will extend unassisted. Do not apply heat or flame to the shock absorbers during removal or component servicing.
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 SECTION 204-01: Front Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Shock Absorber Removal WARNING: All vehicles are equipped with gas pressurized shock absorbers which will extend unassisted. Do not apply heat or flame to the shock absorbers during removal or component servicing.
Page 173 7. Support the front suspension lower arm (3078) with a jack stand. 8. Disconnect the shock absorber (18124) from the spindle (3105). 1. Remove and discard the nuts and bolts. 2. Disconnect the shock absorber. 9. Carefully lower the front suspension lower arm and remove the jack stand. CAUTION: Do not allow the weight of the vehicle to rest on the front brake disc shield.
Page 174 14. Remove the sleeve and the bushing. Installation 1. To install, reverse the removal procedure.
Page 177 SECTION 204-01: Front Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Spring Special Tool(s) Tie-Rod End Remover 211-001 (TOOL-3290-D) or Equivalent Coil Spring Compressor 204-D001 (D78P-5310-A) or Equivalent Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense.
Page 178 CAUTION: Use care not to damage the tie-rod end dust boot. Using the special tool, disconnect the tie-rod from the spindle. 6. Disconnect the front stabilizer bar link (5K483) from the front suspension lower arm (3078). 1. Remove the nut and bushing. 2.
Page 179 CAUTION: Correctly support the power rack and pinion steering gear to avoid damaging the gear and hoses. Position the power rack and steering gear out of the way. 1. Remove the nuts and bolts. 2. Position the steering gear so the front suspension lower arm front bolt can be removed. 9.
Page 180 12. Lower the front suspension lower arm and remove the jack stand. 13. Remove 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.
Page 181 2. Position a jack stand under the front suspension lower control arm inboard of the spring seat and raise the arm into position. 3. NOTE: The front suspension lower arm nuts must be tightened with the suspension at curb height. Install the bolts and nuts.
Page 182 6. Move the jack stand under the front suspension 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.
Page 183 10. Position the intermediate shaft and install the bolt. 11. Connect the stabilizer bar link to the front suspension lower arm. 1. Install the link and bushing. 2. Install the nut. 12. Connect the tie-rod end to the spindle. 1. Install the tie-rod end into the spindle. 2.
Page 185 SECTION 204-02: Rear Suspension 2003 Mustang Workshop Manual SPECIFICATIONS Torque Specifications Description Nm lb-ft lb-in Mustang Rear shock absorber (upper attachment) — Rear shock absorber (lower attachment) — Shock absorber clevis bracket-to-axle nut 108 80 — Upper arm-to-frame bolt —...
Page 186 Axle shaft-to-hub retainer 325 240 — Wheel nuts 129 95 —...
Page 187 SECTION 204-02: Rear Suspension 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Rear Suspension WARNING: All vehicles are equipped with gas pressurized shock absorbers which will extend unassisted. Do not apply heat or flame to the shock absorbers during removal or component servicing.
Page 188 Part Item Number Description 18125 Rear shock absorber — Rear axle driveline vibration damper 5A649 Rear lower suspension arm and bushing (common LH and RH) 5560 Rear spring 4731 Rear axle bumper bracket 4905 Rear axle differential carrier bumper and bracket 5A772 Rear stabilizer bar 5500...
Page 189 SECTION 204-02: Rear Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Wheel Hub —Cobra Special Tool(s) 2-3 Jaw 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...
Page 190 Step Plate Adapter Set 205-DS011 (D80L-630-A) or Equivalent Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. If substitution is necessary, the part must be of the same finish and property class.
Page 191 5. Method two. Using the special tools, remove the hub. 6. Remove the snap ring. 7. Press the wheel bearing from the knuckle. 1. Position the knuckle on the press bed supported by the special tool. 2. Using the appropriate step plate adapter, press the bearing from the knuckle. Installation 1.
Page 192 2. Install the snap ring. CAUTION: The bearing inner race must be supported during hub installation. 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.
Page 193 5. Inspect the bearing dust seal. 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 195 SECTION 204-02: Rear Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Wheel Studs Special Tool(s) C-Frame and Clamp Assembly 211-023 (T74P-3044-A1) Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary.
Page 196 2. Remove the wheel 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 SECTION 204-02: Rear Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Upper Arm Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary.
Page 198 Installation 1. Install the upper arm and bushing to the mounting bracket. 1. Position the arm and bushing. 2. Install a new nut and bolt. Do not tighten at this time. 2. Connect the upper arm and bushing to the axle. 1.
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 201 SECTION 204-02: Rear Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Upper Arm —Cobra Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary.
Page 202 9. NOTE: Mark a new cam bolt in the same position as the old one for assembly reference before discarding the old bolt. Disconnect the upper suspension arm and bushing from the knuckle (5A968/5A969). 1. Remove and discard the nut and bolt. 2.
Page 203 2. Install new bolts and nuts. Do not tighten the nuts at this time. 2. Connect the upper suspension arm and bushing to the knuckle. 1. Position the arm and bushing. 2. Install a new cam bolt and a new nut. Do not tighten the nut at this time. 3.
Page 204 7. Tighten the nuts. 8. Position the cam bolt so the marks are aligned. Tighten the nut. 9. Lower the suspension and 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.
Page 206 SECTION 204-02: Rear Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Lower Arm Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary.
Page 207 2. NOTE: Tighten the lower suspension arm and bushing-to-body 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: Stabilizer Bar
SECTION 204-02: Rear Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Stabilizer Bar Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary.
Page 209 5. Remove and discard the nuts from the stabilizer bar. Installation 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.
Page 211 SECTION 204-02: Rear Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Stabilizer Bar —Cobra Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary.
Page 212 6. Remove the stabilizer bar (5A772) with the stabilizer bar bushings (5493). Installation 1. NOTE: The stabilizer bar bracket bolts and the nuts on the stabilizer bar 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.
Page 213 2. Check wheel alignment. Adjust as necessary. For additional information, refer to Section 204-...
Page 214 SECTION 204-02: Rear Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Link —Stabilizer Bar Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary.
Page 216 SECTION 204-02: Rear Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Wheel Knuckle —Cobra Special Tool(s) Front Hub Remover 205-D070 (D93P-1175-B) or Equivalent Steering Arm Remover 211-003 (T64P-9171-A) Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense.
Page 217 5. Disconnect the parking brake cable and conduit from the parking brake lever. 6. Remove the clip and disconnect 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.
Page 218 10. Remove the nut and bolt and disconnect the shock absorber (18125) from the lower suspension arm and bushing. Discard the nut and bolt. 11. Remove and discard the cotter pin and nut. CAUTION: Do not strike the toe link or the knuckle to disconnect the toe link. The toe link or the knuckle can be damaged.
Page 219 14. NOTE: Mark a new cam bolt in the same position as the old one for assembly reference before discarding the old bolt. Disconnect the upper suspension arm and bushing from the knuckle. 1. Remove and discard the nut and bolt. 2.
Page 220 17. Remove the dust shield, hub, snap ring and bearing from the knuckle. For additional information, refer to Wheel Hub—Cobra in this section. Installation 1. Install the bearing, snap ring, hub and dust shield. For additional information, refer to Wheel Hub—Cobra in this section.
Page 221 5. Connect the toe link to the knuckle. 1. Position the toe link in the knuckle. 2. Install a new nut. 3. Install a new cotter pin. 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.
Page 222 8. Tighten the nut. 9. Make sure the marks on the cam bolt and the upper suspension 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.
Page 223 13. Connect the parking brake cable and conduit to the rear brake caliper and install the clip. 14. Connect the parking brake cable and conduit to the parking brake lever. CAUTION: The axle retainer must be tightened with the brakes applied and the wheels off the ground to make sure of correct bearing seating.
Page 225 SECTION 204-02: Rear Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Toe Link —Cobra Special Tool(s) Steering Arm Remover 211-003 (T64P-9171-A) Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary.
Page 226 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 (5K848) from the knuckle (5A968/5A969). 8. Remove the nut, bolt and the toe link. Discard the bolt and nut. Installation CAUTION: Make sure the hardened washer is installed between the lower suspension arm and bushing and the shock absorber.
Page 227 2. Check wheel alignment. Adjust as necessary. For additional information, refer to Section 204-...
Page 229 SECTION 204-02: Rear Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Spring —Coil Special Tool(s) Hi-Lift Jack 014-00942 or Equivalent Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary.
Page 230 4. Remove the bolt and the parking brake cable bracket. Discard the bolt. Vehicles equipped with a 4.6L 2V engine 5. Remove the stabilizer bar (5A772). For additional information, refer to Stabilizer Bar in this section. All vehicles 6. Support the differential housing with a jack stand. 7.
Page 231 All vehicles 1. NOTE: Inspect the insulators for wear or damage. Install new insulators if necessary. Install the upper insulator on the spring. 2. Install 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.
Page 232 5. Remove the special tool 014-00942. 6. Raise the suspension until the shock absorber is compressed to the alignment mark (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.
Page 233 11. Connect the anti-lock sensor wire. 12. Lower the vehicle.
Page 234 SECTION 204-02: Rear Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Spring —Cobra Special Tool(s) Rotunda Powertrain Lift 014-00765 or Equivalent Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary.
Page 235 8. Disconnect 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 12. Unclip the ABS sensor wires from the subframe. 13. Support the lower suspension arm and bushings (5A649) with jack stands. 14. Remove the nuts, bolts and disconnect the shock absorbers (18125) from the lower suspension arm and bushings. Discard the bolts and nuts. 15.
Page 237 18. Remove and discard the subframe rear bolts. 19. Remove the springs (5560). 1. Carefully lower the subframe with 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.
Page 238 2. Install 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 6. Remove the special tool 014-00765. 7. Support the lower suspension arm and bushings with jack stands. 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.
Page 240 11. Connect the rear brake lines and install the bolts. 12. Connect 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.
Page 241 15. Connect the parking brake cable and conduit to the parking brake levers. 16. Install the driveshaft. For additional information, refer to Section 205-01 17. Install both mufflers. For additional information, refer to Section 309-00 18. Install both wheel and tire assemblies. For additional information, refer to Section 204-04 19.
Page 243 SECTION 204-02: Rear Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Shock Absorber Removal WARNING: All vehicles are equipped with gas pressurized shock absorbers which will extend unassisted. Do not apply heat or flame to the shock absorbers during removal or component servicing.
Page 244 1. Correctly prime the new shock absorber. For additional information, refer to Section 204-00 2. Install a new washer and insulator on the shock 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.
Page 246 SECTION 204-02: Rear Suspension 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Damper Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary.
Page 247 2. Install the damper. 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.
Page 248 5. Install the wheel and tire assembly. For additional information, refer to Section 204-04 6. Lower the vehicle.
Page 249 SECTION 204-04: Wheels and Tires 2003 Mustang Workshop Manual SPECIFICATIONS General Specifications Item Specification Lubricants Silicone Dielectric Compound D7AZ-19A331- ESE-M1C171-A Cleaners Liquid Soap ESR-M99B135-A Professional Choke and Linkage Cleaner ESR-M14P10-A E8AZ-19A501-AA Custom Bright Metal Cleaner ESR-M5B194-B 8A-19522-A Aluminum Wheel Repair Compound E7AZ-...
Page 251: Safety Precautions
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.
Page 253: Wheels And Tires
SECTION 204-04: Wheels and Tires 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Wheels And Tires WARNING: Do not mix different types of tires, such as radial, bias, or bias-belted, on the same vehicle except in emergencies. Vehicle handling can be seriously affected and can result in loss of control.
Page 254 SECTION 204-04: Wheels and Tires 2003 Mustang Workshop Manual DIAGNOSIS AND TESTING Wheels And Tires Inspection and Verification WARNING: A vehicle equipped with a Traction-Lok® differential will always have both wheels driving. If, while the vehicle is being serviced, only one wheel is raised off the ground and the rear axle is driven by the engine, the wheel on the ground could drive the vehicle off the stand or jack.
Page 255 wheel bearing life. brake cooling. New wheels need to be installed when vehicle's wheels: are bent. are cracked. are dented. are heavily corroded. are leaking. have elongated wheel hub bolt holes. have excessive lateral or radial runout. Wheel and tire assemblies are attached by six wheel nuts. It is mandatory to use only the tire sizes recommended on the tire chart attached to the vehicle.
Page 256 Section 204-00 Incorrect tire rotation ADVISE customer of intervals. condition. ROTATE tires. Tires show Tires overinflated. ADJUST air pressure. excess wear in center of tread Other excessive Incorrect tire rotation ADVISE customer of tire wear intervals. condition. ROTATE problems tires. Incorrect tire pressure.
Page 258 SECTION 204-04: Wheels and Tires 2003 Mustang Workshop Manual GENERAL PROCEDURES Wheel Leaks Material Item Specification Professional Choke and WSS-M14P10- Linkage Cleaner F8AZ-19520-AB Aluminum Wheel Repair ESA-M4G280- Compound WARNING: Wheel repairs that use welding or peening are not approved. An inner tube is not an acceptable repair for leaking wheels or tires.
Page 260: Wheel And Tire
SECTION 204-04: Wheels and Tires 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Wheel And Tire Removal CAUTION: Do not use heat to loosen a seized wheel nut (1012). Heat can damage the wheel and wheel bearings. NOTE: To avoid damage or scratching to the center cap, place facing up when removed.
Page 261 Installation WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel and the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control.
Page 263 SECTION 205-00: Driveline System — General Information 2003 Mustang Workshop Manual SPECIFICATIONS Driveline Angles @ Curb Specifications Engine (L) Engine Angle (Deg) Driveshaft Angle (Deg) Pinion Angle (Deg) 2.95 0.55 4.6 (2V) 3.61 0.55 All driveshaft and pinion angles point downward.
Page 265 SECTION 205-00: Driveline System — General Information 2003 Mustang Workshop Manual DIAGNOSIS AND TESTING Driveline System Special Tool(s) Clamp Plate 205-320 (T92L-4851-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)
Page 266 Inspection and Verification Certain axle noise or vibration symptoms are also common to the engine, transmission, wheel bearings, tires, and other parts of the vehicle. For this reason, be sure that the cause of the trouble is in the axle before disassembling, adjusting or repairing the axle. Refer to Section 100-04 Certain driveshaft vibration symptoms are common to the front engine accessory drive (FEAD), the engine, transmission or tires.
Page 267 Repair the axle as necessary. Make sure the axle lubricant is at the correct level. Refer to Specifications in this section. Axle Vent NOTE: If a plugged vent cannot be cleared, install a new one. A plugged vent will cause excessive seal lip wear due to internal pressure buildup. If a leak occurs, check the vent.
Page 268 WARNING: Do not balance the wheels and tires while they are mounted on the vehicle. Possible tire disintegration/differential failure could result, causing personal injury/extensive component damage. Use an off-vehicle wheel and tire balancer only. Most vibration in the rear end is caused by tires or driveline angle. Vibration is a concern with modern, high-mileage tires if they are not "true"...
Page 269 When these conditions exist, check the driveline angles as described in the General Procedures portion of this section. If the tires and driveline angle are not the cause, carry out the NVH tests to determine whether the concern is caused by a condition in the axle. Refer to Section 100-04 Universal Joint (U-Joint) Wear Place the vehicle on a frame hoist and rotate the driveshaft by hand.
Page 270 NOTE: If the axle shaft assembly is removed, check runout of the shaft itself. The forged (unmachined) part of the shaft is allowed to have as much as 3.0 mm (0.120 inch) runout. This alone will not cause a vibration condition. 1.
Page 271 NOTE: A low-pitched rumble normally associated with a worn/damaged wheel bearing can also be caused by tires. A wheel bearing noise can be mistaken for a pinion bearing noise. Check the wheel bearing for a spalled cup, and spalled/damaged rollers. Check the wheel bearing for rotating smoothness and end play.
Page 272 If metal has broken loose, the axle housing must be cleaned to remove particles that will cause damage. At this time, any other new parts in the 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.
Page 273 2. NOTE: Measure the end play with a Dial Indicator with Bracketry and not by feel. Knock is also caused by excessive end play in the axle shafts. Up to 0.762 mm (0.030 inch) is allowed in semi-float axles. The frequency of the knock will be less because the axle shaft speed is slower than the driveshaft.
Page 274 crayon or chalk. 6. While holding the crayon or chalk against the tire, rotate the wheel slowly in the opposite direction until the feeling of driving the rear axle is encountered again. 7. Measure the length of the crayon or chalk mark on the tire. If the length of the mark is 25.4 mm (1 inch) or less, the rear axle backlash is within allowable limits.
Page 275 lubricant type. 205-02B . CLEAN and REFILL the axle to specification. Axle overheating Lubricant level too CHECK the lubricant level. low. FILL the axle to specification. Incorrect or INSPECT the axle for contaminated damage. REPAIR as lubricant type. necessary. CLEAN and REFILL the axle to specification.
Page 276 presence of the vibration. If the vibration is not evident, check the non-driving wheels with a wheel balancer to rule out imbalance as a possible cause. If required, balance the non-driving wheels and repeat the road test. If the vibration is still evident, proceed to Step 2. 2.
Page 277 If the marks are on opposite sides of the driveshaft, the yoke or pinion flange is responsible for the vibration. When installing a new pinion flange, the driveshaft runout must not exceed 0.89 mm (0.035 inch). When runout is within limits, recheck for vibration at road speed. If vibration persists, balance the driveshaft.
Page 278 If no improvement is noted, rotate the clamps in opposite directions, equal distances from the best position determined in Step 8. Separate the clamp heads about 13 mm (1/2 inch) and recheck for vibration at the road speed. Repeat the process with increasing separation until the best combination is found or the vibration is reduced to an acceptable level.
Page 279 off the floor. With the engine off, raise only one rear wheel. Install the special tool on the wheel nuts. Use a torque wrench with a capacity of at least 271 Nm (200 lb-ft) to rotate the axle shaft. Be sure that the transmission is in NEUTRAL, and that one rear wheel is on the floor while the other rear wheel is raised off the floor.
Page 280 Companion Flange Runout Check CAUTION: Pinion bearing preload must be reset if the pinion nut has been loosened or removed for pinion flange reindexing or installation. 1. Raise the vehicle on a twin-post hoist that supports the rear axle. Refer to Section 100-02 2.
Page 281 7. Position the special tool as shown. Turn the Companion Flange Runout Gauge, and locate and mark the high spot on the pinion flange with yellow paint. If the flange runout exceeds 0.25 mm (0.010 inch), remove the pinion flange, reindex the flange one- half turn on the pinion, and reinstall it.
Page 282 2. Use a box wrench on the ring gear bolts as a lever to rotate the ring gear several complete revolutions in both directions or until a clear tooth contact pattern is obtained. 3. Certain types of gear tooth contact patterns on the ring gear indicate incorrect adjustment. Incorrect adjustment can be corrected by readjusting the ring gear or the pinion.
Page 283 Correct pinion position shim that requires a decrease in backlash. Correct pinion position shim that requires an increase in backlash.
Page 284 SECTION 205-00: Driveline System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Driveline Angle Inspection Special Tool(s) Anglemaster II Driveline Inclinometer 164-R2402 or equivalent NOTE: An incorrect driveline angle can cause a vibration or shudder. For additional information, refer Section 100-04 1.
Page 285 7. To check the engine angle, rotate the driveshaft so that the slip yoke ear is parallel 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 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.
Page 287 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).
Page 288 SECTION 205-01: Driveshaft 2003 Mustang Workshop Manual SPECIFICATIONS Torque Specifications Description Nm lb-ft Pinion flange bolts 112 83...
Page 289 SECTION 205-01: Driveshaft 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Driveshaft Item Part Number Description N800594-S100 Bolt (4 req'd) 4635 Universal joint (U-joint) 4602 Driveshaft — Grease seal (part of 4635) — Needle bearings (part of 4635) — Bearing cup (part of 4635) —...
Page 290 wheels. Consists of two single-cardan universal joints, a driveshaft 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 SECTION 205-01: Driveshaft 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Universal Joints The universal joints are: lubed-for-life design and require no lubrication. equipped with nylon thrust washers, located at each base of the bearing cup, which control end play, position the needle bearing and improve grease movement.
Page 293 SECTION 205-01: Driveshaft 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Driveshaft Material Item Specification Threadlock® and WSK-M2G351-A5 (type Sealer E0AZ-19554-AA Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section 100-02 2. Carry out the following: 1.
Page 294 Lower the rear end of the driveshaft to clear the rear axle housing. Pull the driveshaft rearward 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.
Page 295 SECTION 205-01: Driveshaft 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Driveshaft —Cobra Material Item Specification Threadlock® and Sealer WSK-M2G351-A5 (type E0AZ-19554-AA Silicone Lubricant (Aerosol) ESR-M13P4-A F5AZ-19553-AA Removal and Installation 1. Raise and support the vehicle. For additional information, refer to Section 100-02 2.
Page 296 2. Remove the four bolts. CAUTION: The driveshaft centering socket yoke fits tightly on 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.
Page 298 SECTION 205-01: Driveshaft 2003 Mustang Workshop Manual DISASSEMBLY AND ASSEMBLY Driveshaft Slip Yoke Special Tool(s) Installer/Remover, C Frame and Screw 205-086 (T74P-4635-C) Disassembly 1. Remove the driveshaft (4602). For additional information, refer to Driveshaft in this section. CAUTION: Under no circumstances is the driveshaft assembly to be clamped in the jaws of a vise or similar holding fixture.
Page 299 5. Remove all four of the snap rings. 6. NOTE: If necessary, use a pair of pliers to remove a bearing cup if it cannot be pressed out all the way. Remove the driveshaft slip yoke (4841). 1. Position the driveshaft slip yoke in the U-joint tool. 2.
Page 300 Check the needle bearings for correct positioning. 2. Position the new spider in the driveshaft yoke. 3. Using the special tool, press the bearing cup to just below the snap ring groove. 2. 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 black snap rings, as required.
Page 302 SECTION 205-01: Driveshaft 2003 Mustang Workshop Manual DISASSEMBLY AND ASSEMBLY Universal Joint —Single Cardan, Flange Yoke Special Tool(s) Installer/Remover, C Frame and Screw 205-086 (T74P-4635-C) Disassembly 1. Remove the driveshaft (4602). For additional information, refer to Driveshaft in this section.
Page 303 6. Remove the driveshaft flange yoke. 1. Position the driveshaft flange yoke in the U-joint tool. 2. Press out a bearing cup. 3. Remove the driveshaft flange yoke. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the driveshaft flange yoke. 7.
Page 304 2. Position the new spider in the driveshaft 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. 2. Inspect the driveshaft flange yoke. Install new if necessary. 3.
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 SECTION 205-02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring 2003 Mustang Workshop Gear Manual SPECIFICATIONS General Specifications Item Specification Lubes and Sealers SAE 80W-90 Premium Rear Axle Lubricant XY- WSP-M2C197-A 80W90-QL Premium Long-Life Grease XG-1-C ESA-M1C75-B Rust Penetrant and Inhibitor F2AZ-19A501-A...
Page 307 Bolt retaining the bearing cap to the differential case — Bolt retaining the ring gear to the differential case —...
Page 308 SECTION 205-02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring 2003 Mustang Workshop Gear Manual DESCRIPTION AND OPERATION Rear Drive Axle and Differential Item Part Number Description 4236 Differential side gear 4228 Differential side gear thrust washer 4221 Differential bearing...
Page 309 4222 Differential bearing cup 4067 Differential bearing shim 4216 Rear axle differential gear case bolt 4204 Differential case — Ring gear (part of 4209) — Bearing cap (part of 4010) 4010 Rear axle housing 373098-S Filler plug 4662 Collapsible spacer 4670 Rear axle drive pinion shaft oil slinger 4676...
Page 310 The axle housing assembly consists of a cast center section with two steel tube assemblies and a stamped differential housing cover (4033). The differential housing cover uses silicone sealant as a gasket. The hypoid-design gearset consists of 7.5-inch ring gear (4209) and a drive pinion gear (4209). Two opposed tapered roller bearings support the drive pinion in the axle housing (4010).
Page 311 SECTION 205-02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring 2003 Mustang Workshop Gear Manual IN-VEHICLE REPAIR Axle Shaft Removal 1. Raise and support 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.
Page 312 Remove the axle shaft. Installation 1. Lubricate the lip of the wheel bearing oil seal Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA- M1C75-B. CAUTION: Do not damage the wheel bearing oil seal. Install the two axle shafts.
Page 313 1. Position the two U-washers on the button end of the axle shaft. 2. Pull the axle shaft outward. 4. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Install the differential pinion shaft.
Page 315 SECTION 205-02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring 2003 Mustang Workshop Gear Manual IN-VEHICLE REPAIR Rear Wheel Bearing and Axle Shaft Oil Seal 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...
Page 316 2. Using the special tools, install the 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.
Page 318 SECTION 205-02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring 2003 Mustang Workshop Gear Manual IN-VEHICLE REPAIR Drive Pinion Flange and Drive Pinion Seal Special Tool(s) 2-Jaw Puller 205-D072 (D97L-4221-A) or equivalent Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Installer, Drive Pinion Flange...
Page 319 Section 205-01 5. Install an Nm (inch/pound) torque wrench on the nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions. 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.
Page 320 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.
Page 321 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 equivalent meeting Ford specification WSK- M2G351-A5 to the threads of the original bolts. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot.
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 CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. Apply a continuous bead of sealant of the specified thickness to the differential housing cover. Use Clear Silicone Rubber F7AZ-19554-CA or equivalent meeting Ford specifications ESB-M4G92-A.
Page 324 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-M2C197-A. 5. Lower the vehicle.
Page 326 SECTION 205-02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring 2003 Mustang Workshop Gear Manual IN-VEHICLE REPAIR Axle Housing Bushing Special Tool(s) Axle Suspension Bushing Set 204-S030 (T78P-5638-A) Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense.
Page 327 2. 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 SECTION 205-02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring 2003 Mustang Workshop Gear Manual IN-VEHICLE REPAIR Drive Pinion Special Tool(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)
Page 329 equivalent Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Installer, Drive Pinion Bearing Cone 205-005 (T53T-4621-C) Installer, Drive Pinion Bearing 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...
Page 330 Removal 1. Remove the differential assembly from the differential housing. For additional information, refer Differential Case in this section. CAUTION: Record the torque necessary to maintain rotation of the drive pinion gear through several revolutions prior to removing the pinion flange (4851). Remove the pinion flange.
Page 331 6. Remove the outer differential pinion bearing. 7. Remove and discard the collapsible spacer (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.
Page 332 sides of the cup to prevent the cup from cocking in the casting. Installation Using special tool 205-054 NOTE: This is the preferred method for installing the pinion bearing cups. If necessary, proceed to Using special tools 205-153, 205-054, and 205-D055 in this procedure for an alternate method. 1.
Page 333 Check that the cups have seated correctly in their bores. Using special tools 205-153, 205-054, and 205-D055 NOTE: This is an alternate method for installing the pinion bearing cups. Carry out this procedure if pinion bearing cup installation was not done in the previous steps. 4.
Page 334 Setting pinion depth 7. NOTE: Apply only a light oil film on the differential pinion bearings before assembling the tools. Assemble and position the following in the differential housing. 1. Position the Adapter for 205-S127. 2. Position the Adapter for 205-S127. 3.
Page 335 Part Item Number Description 205-109 Adapter for 205-S127 (T76P-4020-A9) 205-105 Adapter for 205-S127 (T76P-4020-A3) (1.612 inch O.D.) 4630 Rear (inner) pinion bearing 205-125 Adapter for 205-S127 (T78P-4020-A15) (0.894 inch thick) 205-110 Adapter for 205-S127 (T76P-4020-A10) (1.7 inch thick) 4621 Front (outer) pinion bearing 205-111 Adapter for 205-S127 (T76P-4020-A11) 9.
Page 336 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.
Page 337 16. Install 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 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 23. Install the differential assembly in the differential housing. For additional information, refer to Differential Case in this section. 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 equivalent meeting Ford specification WSK-...
Page 340 M2G351-A5 to the threads of the original bolts. CAUTION: The driveshaft 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.
Page 341 SECTION 205-02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring 2003 Mustang Workshop Gear Manual IN-VEHICLE REPAIR Differential Case 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...
Page 342 Remove the axle shafts. For additional information, refer to Axle Shaft in this section. 3. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage. 4. Rotate the differential assembly to check for roughness indicating bearing/gear damage. 5.
Page 343 (4010) to protect the machined surface from damage. Using a pry bar and a wood block, remove the differential assembly from the differential housing. 8. Remove the 10 bolts. CAUTION: Do not damage the threads in the bolt holes. Insert a punch in the bolt holes, and drive off the ring gear. 10.
Page 344 12. Position the special tool. 1. Rotate the differential case to verify that the differential bearings (4221) have seated correctly. 2. Position the special tool. 13. Measure and note the differential case runout. 1. Rotate the differential case. 2. Note the runout. If the runout does not exceed the specification, install a new ring gear and drive pinion gear.
Page 345 16. Using the special tool, install the new differential bearings. 17. Position the differential assembly, including 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.
Page 346 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 pinion depth set and the pinion installed, place the differential assembly in the...
Page 347 4. Install a differential bearing shim on the left side. CAUTION: Always install the bearing caps in their identical 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.
Page 348 7. Install the right side bearing cap and tighten the left side and right side bolts to specification. 8. Rotate the differential assembly several times to verify that the differential bearings have seated correctly. Measuring backlash 9. Using the special tools, measure the ring gear backlash. If backlash is within the specification, refer to Backlash within specification in this procedure.
Page 349 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...
Page 350 12. Rotate the differential assembly several times to verify that the differential bearings seated correctly. 13. Measure the backlash. Refer to Measuring backlash in this procedure. Backlash not within specification 14. To increase or decrease the backlash, remove the bearing caps and install a thicker shim and thinner shim accordingly.
Page 351 16. Rotate the differential several times to verify that the differential bearings have seated correctly. 17. Using the special tools, recheck the backlash. If backlash is within the specification, refer to Backlash within specification in this procedure. If backlash is not within the specification, repeat Backlash not within specification in this procedure.
Page 352 20. Install the bearing caps and bolts. 21. Using the special tools, recheck the backlash. The specification shown is the full allowable 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.
Page 353 24. Lower the vehicle.
Page 354: Axle Assembly
SECTION 205-02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring 2003 Mustang Workshop Gear Manual REMOVAL AND INSTALLATION Axle Assembly Removal and Installation CAUTION: The vehicle must be on level ground and at curb height. Mark the rear shock absorbers relative to their protective sleeve.
Page 355 5. 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 CAUTION: Index-mark the brake discs and the wheel studs prior to brake disc removal.
Page 356 8. Remove and discard the nuts and bolts retaining the shock absorbers to 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.
Page 357 CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK- M2G351-A5 to the threads of the original bolts. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot.
Page 359 SECTION 205-02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring 2003 Mustang Workshop Gear Manual DISASSEMBLY AND ASSEMBLY Differential Case and Ring Gear 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...
Page 360 4. Using the special 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 1. Lubricate the differential side gear thrust washers and the differential side gear 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.
Page 362 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 8. 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. 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 0.25 mm (0.010 in) T.I.R. If it is necessary to refill a Traction-Lok® axle with new lubricant, add 118 ml (4 oz) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A before filling the axle with the new lubricant.
Page 366 Oil filler plug — Pinion bearing preload (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 — Bolt retaining the bearing cap to the differential case — Bolt retaining the ring gear to the differential case —...
Page 367 SECTION 205-02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring 2003 Mustang Workshop Gear Manual DESCRIPTION AND OPERATION Rear Drive Axle and Differential Item Part Number Description 4236 Differential side gear 4228 Differential side gear thrust washer 4221 Differential bearing...
Page 368 4222 Differential bearing cup 4067 Differential bearing shim 4216 Rear axle differential gear case bolt 4204 Differential case — Ring gear (part of 4209 gearset) — Bearing cap (part of 4010) 4010 Rear axle housing 373098-S Filler plug 4662 Collapsible spacer 4670 Rear axle drive pinion shaft oil slinger 4676...
Page 369 The axle housing assembly consists of a cast center section with two steel tube assemblies and a stamped differential housing cover (4033). The differential housing cover uses silicone sealant as a gasket. The hypoid-design gearset consists of 8.8-inch ring gear (4209) and a drive pinion gear (4209). Two opposed tapered roller bearings support the drive pinion in the axle housing (4010).
Page 370 SECTION 205-02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring 2003 Mustang Workshop Gear Manual IN-VEHICLE REPAIR Axle Shaft Removal 1. Raise and support 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.
Page 371 Remove the axle shaft. Installation 1. Lubricate the lip of the wheel bearing oil seal Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA- M1C75-B. CAUTION: Do not damage the wheel bearing oil seal. Install the two axle shafts.
Page 372 1. Position the two U-washers on the button end of the axle shaft. 2. Pull the axle shaft outward. 4. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to installation. Install the differential pinion shaft.
Page 374 SECTION 205-02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring 2003 Mustang Workshop Gear Manual IN-VEHICLE REPAIR Rear Wheel Bearing and Axle Shaft Oil Seal 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...
Page 375 2. Using the special tools, install the 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.
Page 377 CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. Apply a continuous bead of sealant of the specified thickness to the differential housing cover. Use Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A.
Page 378 2. Install the 10 bolts. 4. NOTE: If it is necessary to refill a Traction-Lok® axle with new lubricant, add 118 ml (4 oz) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST- M2C118-A before filling the axle with the new lubricant.
Page 380 SECTION 205-02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring 2003 Mustang Workshop Gear Manual IN-VEHICLE REPAIR Axle Housing Bushing Special Tool(s) Axle Suspension Bushing Set 204-S030 (T78P-5638-A) Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major service expense.
Page 381 2. 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 SECTION 205-02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring 2003 Mustang Workshop Gear Manual IN-VEHICLE REPAIR Drive Pinion Special Tool(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)
Page 383 equivalent Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Installer, Drive Pinion Bearing Cone 205-005 (T53T-4621-C) Installer, Drive Pinion Bearing 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)
Page 384 Puller, Bearing 205-D064 (D84L-1123-A) or equivalent Removal 1. Remove the differential assembly from the differential housing. For additional information, refer Differential Case in this section. CAUTION: Record the torque necessary to maintain rotation of the drive pinion gear through several revolutions prior to removing the pinion flange (4851). Remove the pinion flange.
Page 385 6. Remove the outer differential pinion bearing. 7. Remove and discard the collapsible spacer (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.
Page 386 10. Using the special tools, remove the inner rear axle pinion bearing cup (4628). Installation Using special tool 205-024 NOTE: This is the preferred method for installing the pinion bearing cups. If necessary, proceed to Using special tools 205-153, 205-024, 205-231, and 205-D055 in this procedure for an alternate method.
Page 387 the cup, remove and reseat the cup. Check that the cups have seated correctly in their bores. Using special tools 205-153, -024, -231, and -D055 NOTE: This is an alternate method for installing the pinion bearing cups. Carry out this procedure if pinion bearing cup installation was not done in the previous steps.
Page 388 Setting pinion depth 7. NOTE: Apply only a light oil film on the differential pinion bearings before assembling the tools. Assemble and position the following in the differential housing. Part Item Number Description 205-109 Adapter for 205-S127 (T76P-4020-A9) 205-105 Adapter for 205-S127 (T76P-4020-A3) (1.612 inch O.D.) 4630 Rear (inner) pinion bearing...
Page 389 Tighten the special tool to specification. 9. NOTE: Offset the special tool to obtain an accurate reading. Rotate the special tool several half-turns to make sure the differential pinion bearings seat correctly and position the special tool as shown. 10. Install the special tool. 1.
Page 390 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 the drive pinion gear. 13.
Page 391 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. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove it and install a new one.
Page 392 19. Lubricate the pinion flange splines. Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-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 393 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 equivalent meeting Ford specification WSK- M2G351-A5 to the threads of the original bolts. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot.
Page 395 SECTION 205-02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring 2003 Mustang Workshop Gear Manual IN-VEHICLE REPAIR Differential Case 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...
Page 396 Remove the axle shafts. For additional information, refer to Axle Shaft in this section. 3. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage. 4. Rotate the differential assembly to check for roughness indicating bearing/gear damage. 5.
Page 397 (4010) to protect the machined surface from damage. Using a pry bar and a wood block, remove the differential assembly from the differential housing. 8. Remove the 10 bolts. CAUTION: Do not damage the threads in the bolt holes. Insert a punch in the bolt holes, and drive off the ring gear. 10.
Page 398 12. Position the special tool. 1. Rotate the differential case to verify that the differential bearings (4221) have seated correctly. 2. Position the special tool. 13. Measure and note the differential case runout. 1. Rotate the differential case. 2. Note the runout. If the runout does not exceed the specification, install a new ring gear and drive pinion gear.
Page 399 16. Using the special tool, install the new differential bearings. 17. Position the differential assembly, including 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.
Page 400 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 pinion depth set and the pinion installed, place the differential assembly in the...
Page 401 4. Install a differential bearing shim on the left side. CAUTION: Always install the bearing caps in their identical 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.
Page 402 7. Install the right side bearing cap and tighten the left side and right side bolts to specification. 8. Rotate the differential assembly several times to verify that the differential bearings have seated correctly. Measuring backlash 9. Using the special tools, measure the ring gear backlash. If backlash is within the specification, refer to Backlash within specification in this procedure.
Page 403 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...
Page 404 12. Rotate the differential assembly several times to verify that the differential bearings have seated correctly. 13. Measure the backlash. Refer to Measuring backlash in this procedure. Backlash not within specification 14. To increase or decrease the backlash, remove the bearing caps and install a thicker shim and thinner shim accordingly.
Page 405 16. Rotate the differential several times to verify that the differential bearings have seated correctly. 17. Using the special tools, recheck the backlash. If backlash is within the specification, go to Backlash within specification in this procedure. If backlash is not within the specification, repeat Backlash not within specification in this procedure.
Page 406 20. Install the bearing caps and bolts. 21. Using the special tools, recheck the backlash. The specification shown is the full allowable 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.
Page 407 24. Lower the vehicle.
Page 408 3. Remove 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...
Page 409 6. Disconnect the rear axle drive line vibration damper from the axle. 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 CAUTION: Index-mark the driveshaft flange and pinion flange (4851) to maintain initial balance during installation.
Page 410 9. Remove the stabilizer bar. For additional information, refer 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 12. Remove and discard the nuts and bolts retaining the shock absorbers 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.
Page 412 CAUTION: Install the driveshaft with new bolts. If new bolts are not available, apply Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK- M2G351-A5 to the threads of the original bolts. CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange pilot.
Page 414 SECTION 205-02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring 2003 Mustang Workshop Gear Manual DISASSEMBLY AND ASSEMBLY Differential Case and Ring Gear —Conventional 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...
Page 415 4. Using the special 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 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.
Page 417 3. Position the differential side gear and thrust washer assemblies in the differential case. 4. Engage 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.
Page 418 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...
Page 419 section.
Page 420 SECTION 205-02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring 2003 Mustang Workshop Gear Manual DISASSEMBLY AND ASSEMBLY Differential Case and Ring Gear —Traction-Lok® 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)
Page 421 CAUTION: Do not damage the threads in the bolt holes. Insert 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). WARNING: Due to the spring tension, use care when removing the differential...
Page 422 clutch spring (4214). Failure to follow these instructions may result in personal injury. Remove the differential clutch spring. 7. Remove the differential gears. 1. Remove the two differential pinion gears (4215). 2. Remove the two differential side gears (4236). 3. Remove the two differential pinion thrust washers (4230). CAUTION: Keep the differential clutch packs (4947) in order.
Page 423 Clean and inspect the differential clutch packs for wear and damage and install new parts as necessary. Assembly CAUTION: 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.
Page 424 3. Place the base portion of the special tool in a vise. 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.
Page 425 6. Install the nut. 7. NOTE: Clutch Pack Rebuild Kit F5AZ-4947-A is available for this application. Select and insert the 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...
Page 426 11. Install the differential 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 14. Mount the differential 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.
Page 428 17. Install the bolts. Apply Stud and 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 SECTION 205-02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual SPECIFICATIONS General Specifications Item Specification Lubricants/Adhesive/Sealants Premium Long-Life Grease XG-1-C ESA-M1C75-B SAE 75W-140 High Performance Rear Axle Lubricant F1TZ- WSL-M2C192-A 19580-B Additive Friction Modifier C8AZ-19B546-A EST-M2C118-A Clear Silicone Rubber F7AZ-19554-CA...
Page 430 Pinion bearing preload — (drive pinion collapsible spacer) used bearings New pinion bearings 1.8-3.2 — 16-29 Traction-Lok® clutch gauge nut — Initial minimum breakaway torque — Use Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification WSK- M2G349-A1. With pinion flange yoke seal.
Page 431 SECTION 205-02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Rear Drive Axle and Differential Part Item Number Description 4067 Differential bearing shim 4222 Differential bearing cup 4204 Differential case 4216 Differential ring gear case bolt...
Page 432 4033 Differential housing cover 4B416 Inboard CV joint stub shaft pilot bearing housing seal 4B413 Inboard CV joint stub shaft pilot bearing 4010 Differential housing 4662 Differential drive pinion collapsible spacer 4670 Rear axle drive pinion shaft oil slinger 4851 Rear axle pinion flange 389546- Pinion nut...
Page 433 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.
Page 434 SECTION 205-02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Stub Shaft Pilot Bearing and Seal 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)
Page 435 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. CAUTION: Installation without the correct tools can result in early bearing failure. Place the inboard CV joint stub shaft pilot bearing onto the special tools.
Page 436 5. Lubricate the lip of the new inboard CV joint stub shaft pilot bearing housing seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA- M1C75-B. CAUTION: Installation without the correct tools can result in early seal failure.
Page 438 SECTION 205-02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Drive Pinion Flange Special Tool(s) 2-Jaw Puller 205-D072 (D97L-4221-A) or equivalent Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Installer, Drive Pinion Flange 205-002 (TOOL-4858-E) or...
Page 439 5. Install an Nm (inch/pound) torque wrench on the nut and record the torque necessary to maintain rotation of the drive pinion gear through several revolutions. 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.
Page 440 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.
Page 441 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 equivalent meeting Ford specification WSK- M2G351-A5 to the threads of the original bolts. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot.
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 Install gripping pliers 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. CAUTION: Installation without the proper tool can result in early seal failure.
Page 444 CAUTION: If the rear axle drive pinion 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 SECTION 205-02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Axle Housing 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) Removal CAUTION: The vehicle must be on level ground and at curb height.
Page 446 2. Raise and support the vehicle. For additional information, refer to Section 100-02 3. Remove the rear wheel and tire assemblies. For additional information, refer to Section 204-04 4. Remove the exhaust system. For additional information, refer to Section 309-00 5.
Page 447 Disconnect the parking brake cable and conduit from the parking brake lever and the caliper. For additional information, refer to Section 206-05 8. Separate the parking brake cable and conduit from the knuckle. 9. Remove the rear brake disc. For additional information, refer to Section 206-04 Remove the rear brake caliper and support bracket from the knuckle as an assembly.
Page 448 CAUTION: Do not strike the toe link or the knuckle to disconnect the toe link from the knuckle. Using the special tool, disconnect the toe link from the knuckle. 15. Mark the cam bolt position relative to the upper suspension arm and bushing. 16.
Page 449 17. NOTE: Mark the new cam bolt in the same position as the old one for assembly reference before discarding the old bolt. Disconnect the knuckle from upper suspension arm and bushing. 1. Remove and discard the nut and bolt. 2.
Page 450 21. Insert the special tool 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 CAUTION: Do not damage the axle vent hose. Lower the rear axle 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.
Page 452 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 equivalent meeting Ford specification WSK- M2G351-A5 to the threads of the original bolts. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot.
Page 453 CAUTION: Differential seal damage will occur if installing the halfshaft without the special tool. Install the special tool. 9. Position the halfshaft for installation. 10. Seat the CV joint stub shaft in the differential side gear. 1. Slide the stub shaft into the differential housing until the shaft splines are past the differential seal.
Page 454 CAUTION: Do not tighten the fastener at this time. Connect the knuckle to the upper suspension arm and bushing. 1. Position the knuckle. 2. Install the new cam bolt and nut. CAUTION: Do not tighten the fastener at this time. Connect the knuckle to the lower suspension arm and bushing.
Page 455 CAUTION: Install the hardened washer 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. Position the shock absorber, and install the bolt and the new nut. 15.
Page 456 21. Apply Anti-Seize 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.
Page 457 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 refill capacity is 1.23-1.37 liters (2.6-2.9 pints). 29. Lower the vehicle.
Page 459 SECTION 205-02C: Rear Drive Axle/Differential — Ford 8.8-Inch IRS 2003 Mustang Workshop Manual DISASSEMBLY AND ASSEMBLY Axle Special Tool(s) 2-Jaw Puller 205-D072 (D97L-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)
Page 460 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Spreader, Differential Carrier 205-001 (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)
Page 461 Gauge, Differential Bearing 205-338 (T93P-4222-A) Installer, Drive Pinion Bearing Cone 205-005 (T53T-4621-C) Installer, Drive Pinion Bearing 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 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) Disassembly Initial disassembly 1. Remove the differential housing cover (4033) and drain the lubricant into a suitable container. 2. Wipe the lubricant from the internal working parts and inspect the parts for wear and damage. 3.
Page 463 CAUTION: Do not damage the aluminum differential housing (4010) while carrying out these procedures. Using the special tools, mount the differential housing to a work bench. 1. Attach the special tools to the differential housing with four bolts that retain the differential housing cover to the differential housing.
Page 464 1. Adjust the special tool to zero. 2. Tighten the screw until the differential housing is spread to the specification. 3. Remove the special tools. CAUTION: Mark the position and location of the differential bearing caps as the arrows may not be visible. Always install the differential bearing caps in their identical location and position.
Page 465 through several revolutions prior to removing the rear axle pinion flange (4851). Remove the rear axle pinion flange. For additional information, refer to Drive Pinion Flange this section. 11. Using a screwdriver, force the rear axle drive pinion seal metal flange up and strike it with a hammer.
Page 466 16. Using the special tool and a suitable press, remove the pinion bearing (4630). 1. Position the special tool under the pinion bearing. 2. Using a press, remove the pinion bearing. 17. NOTE: Using a micrometer, measure the drive pinion bearing adjustment shim thickness. Use this measurement as a reference to compare to the shim gauge reading taken prior to installing the pinion bearing.
Page 467 19. If the differential ring gear backface runout measurement, taken at the beginning of this procedure, did not exceed the specification, proceed to Final disassembly in this procedure. If the differential ring gear backface runout measurement, taken at the beginning of this procedure, exceeded the specification, the cause may be a warped differential ring gear, a damaged differential case, or loss of differential bearing preload.
Page 468 23. NOTE: Apply pressure toward the left side to fully seat the differential bearing cup. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim selected can be assembled with a slight drag feel. 24.
Page 469 26. Using the special tool, measure and record the differential ring gear backface runout. If the runout does not exceed the specification, the cause of the original excessive runout was due to a loss of differential bearing preload. Proceed to Final disassembly in this procedure.
Page 470 30. Install the differential case. Rotate the differential case to seat the differential bearings. 31. Using the special tool, measure the differential case flange runout. If the runout does not exceed the specification, the cause of the original excessive runout is the differential ring gear.
Page 471 CAUTION: Do not damage the bolt hole threads. 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.
Page 472 WARNING: The differential clutch spring (4214) is under tension. Remove the spring carefully. Failure to follow these instructions may result in personal injury. Remove the differential clutch spring. 37. Remove the differential gears. 1. Remove the two differential pinion gears (4215) and pinion thrust washers (4230). 2.
Page 473 3. Tighten the special tool to fully seat the bearing cup(s) in the bore(s). 3. NOTE: Apply a light film of SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580- B or equivalent meeting Ford specification WSL-M2C192-A on the front and rear pinion...
Page 474 bearings. Install the pinion bearings and special tools as shown. Item Part Number Description 205-109 Adapter for 205-S127 205-105 Adapter for 205-S127 4630 Rear (inner) pinion bearing 205-129 Adapter for 205-S127 205-110 Adapter for 205-S127 4621 Front (outer) pinion bearing 205-111 Adapter for 205-S127 4.
Page 475 Rotate the special tool several half turns to seat the pinion bearings. Position the special tool as shown. 6. Install the special tool. 1. Position the special tool on the differential housing differential bearing seat. 2. Install the differential bearing caps. 3.
Page 476 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. Using the special tool, install the new rear axle drive pinion seal. 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.
Page 477 1. 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. 2. Position the rear axle pinion flange. 16. Using the special tool, install the rear axle pinion flange.
Page 478 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.
Page 479 20. Place the base 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 23. Install the special tool over the disc and differential clutch pack. 24. Install the nut. 25. Select and insert the 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...
Page 481 26. Remove the special tool from the differential clutch pack and differential side gear assembly. 27. Install the shim(s) on the differential clutch pack and differential side gear assembly. 28. Install the differential side gear assemblies in the differential case. 29.
Page 482 31. NOTE: If a new bolt is unavailable, coat the original bolt threads with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5 prior to final installation. Install the differential pinion shaft and install a new bolt finger-tight. 32. Mount the differential case and the special tool in a vise. Using the special tool, check the torque necessary to rotate one differential side gear.
Page 483 CAUTION: Do not damage the aluminum differential housing while carrying out these procedures. Place the differential case with the special tools in the differential housing. 35. Position the special tool on the outside mounting hole. 36. NOTE: Repeat this step until obtaining a consistent reading. Measure the total end play.
Page 484 Left Differential Bearing Right Differential Bearing Height Height 8.8-inch Aluminum Axle Example Actual Example Actual Master bearing height 0.8695 0.8695 0.8695 0.8695 Line-D Actual bearing -0.8478 Minus (-) -0.8491 Minus (-) height Line-E Difference 0.0217 0.0204 Left Side Right Side 8.8-inch Aluminum 8.8-inch Aluminum Axle...
Page 485 39. Install the differential ring gear. 1. Place the differential ring gear on the differential case. 2. Hand start three bolts to align the holes in the 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.
Page 486 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 the bolt threads, and reinstall the bolts. 45. NOTE: Measure the stand height of both differential bearings prior to installation.
Page 487 1. Place the special tool base in a soft-jawed vise with the bearing mounting surface above the vise jaws. 2. Position the differential bearing on the special tool base. 3. Attach the bolt, spring, washers and spacer. 4. Tighten the bolt. 46.
Page 488 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.
Page 489 53. NOTE: Tighten the bolts prior to releasing the carrier spreader. Install 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.
Page 490 1. Attach the special tool. 2. Position the special tool tip centrally on a drive tooth. 3. Zero the indicator. 4. Turn the differential ring gear without turning the drive pinion gear. Record the indicator reading. The allowable backlash is 0.203 mm ( 0.008 in) to 0.330 mm ( 0.013 in) and must not very more than 0.1016 mm (0.004 in) between points measured.
Page 491 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 Differential Shim Size Chart — 4067 — Dimension A Numbers of Stripes and Color Code Inch 2—C-COAL 7.7978-7.8105 0.3070-0.3075 1—C-COAL 7.7470-7.7597 0.3050-0.3055 5—BLU 7.6962-7.7089 0.3030-0.3035 4—BLU 7.6454-7.6581 0.3010-0.3015 3—BLU...
Page 492 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. CAUTION: First fill the rear axle (4001) with 118 ml (4 oz) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A.
Page 494 SECTION 205-05: Rear Drive Halfshafts 2003 Mustang Workshop Manual SPECIFICATIONS General Specifications Item Specification Halfshaft assembled length 817.6 mm (32.19 in) Torque Specifications Description Nm lb-ft Tie-rod end to knuckle Shock absorber to suspension lower arm 133 98 Suspension upper arm and bushing to knuckle 90...
Page 495 SECTION 205-05: Rear Drive Halfshafts 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Rear Drive Halfshafts The rear wheel drive halfshaft system consists of and operates as follows: Halfshafts (4K138) transmit engine torque from the rear axle housing to the rear wheels.
Page 496 Item Part Number Description 4B422 Driveshaft bearing retainer circlip 2C189 Rear brake anti-lock sensor indicator — Retaining ring (part of 4B402) 4B478 Boot clamp (large inboard) — Rear axle shaft inner boot (part of 4B402) 4B478 Boot clamp (small inboard) 4B478 Boot clamp (small outboard) —...
Page 497 Do not drop assembled halfshafts. The impact will cut the boots from the inside without evidence of external damage. Inspect all machined surfaces and splines for damage. Wheel and Tire Balancing, Rear WARNING: Do not balance the rear wheels and tires while mounted on the vehicle. Possible tire disintegration, differential or halfshaft failure can result, causing personal injury or extensive component damage.
Page 498 SECTION 205-05: Rear Drive Halfshafts 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Halfshaft 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 211-003 (T64P-3590-F) Removal NOTE: This procedure applies to both the LH and RH halfshafts.
Page 499 2. Raise and support the vehicle. For additional information, refer to Section 100-02 3. Remove the rear wheel and tire assembly. For additional 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.
Page 500 8. Disconnect the shock absorber at the suspension lower 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.
Page 501 12. Using the special tool, press the outboard CV joint until it is loose in the hub. CAUTION: Do not over-angulate the outboard CV joint or damage the boot. While lowering the knuckle, remove the CV joint from the hub. CAUTION: The crown on the tool forks must face away from the axle housing.
Page 502 Installation 1. NOTE: This procedure applies to both the LH and RH halfshafts. Install a new driveshaft bearing retainer circlip. 2. Remove the special tool. CAUTION: Differential seal damage will occur if installing the halfshaft without the special tool installed. Install the special tool.
Page 503 4. Position the halfshaft for installation. 5. Seat the CV joint stub shaft in the differential side gear. 1. Slide the stub shaft into the axle housing until the shaft splines are past the differential seal. 2. Remove the special tool. 3.
Page 504 7. Connect the suspension upper arm and bushing to the knuckle. 1. Position the suspension upper arm and bushing on the knuckle. 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.
Page 505 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...
Page 506 16. Install 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 SECTION 205-05: Rear Drive Halfshafts 2003 Mustang Workshop Manual DISASSEMBLY AND ASSEMBLY Halfshaft Joint Special Tool(s) Driver 205-199 (T83T-3132-A1) Hub Bearing Cup Replacer 205-147 (T80T-4000-P) Sensing Ring Replacer 206-041 (T89P-20202-A) Disassembly CAUTION: Do not disassemble the halfshaft assembly. Install a new assembly if worn or damaged.
Page 508 Assembly 1. Using the special tool and a hammer, install the new dust seal assembly, if removed. CAUTION: Place only the inboard CV joint outer race land on 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.
Page 510 SECTION 206-00: Brake System — General Information 2003 Mustang Workshop Manual SPECIFICATIONS Torque Specifications Description 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 — Rear master cylinder brake tube 15-20 11-14 —...
Page 511 SECTION 206-00: Brake System — General Information 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Brake System Component Locations Part Item Number Description 2C346 Four wheel anti-lock brake system (4WABS)
Page 512 hydraulic control unit and control module assy (non- traction) 2C353 Four wheel anti-lock brake system (4WABS) hydraulic control unit and control module assy (traction) 2B559 Hydro-Boost brake booster and brake master cylinder assy 2B195 Vacuum brake booster and brake master cylinder assy 2K327 Rear disc brake assy...
Page 513 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 the brake warning indicator is functional. For...
Page 514 in the brake master cylinder reservoir are also indicators of system concerns. If a wheel is locked and the vehicle must be moved, open a bleeder screw at the locked wheel (1007) to let out enough fluid to relieve the pressure. Close the bleeder screw. This bleeding operation may release the brakes but will not correct the cause of trouble.
Page 515 Power brake booster Brake pedal linkage Vacuum booster hose Tires Foreign material For low or spongy brake pedal concerns: check and, if necessary, refill the brake master cylinder reservoir. bleed the brake system and retest the brake pedal feel. if the brake pedal is still low or feels spongy, check the brake pedal mounting for looseness and correct installation.
Page 516 not machine a new brake disc. 7. For vehicles with a two-piece hub and brake disc assembly: Match-mark before disassembly. Remove the brake disc. Using a die grinder with a mild abrasive (Scotch Brite® type), remove any rust or corrosion from the hub and brake disc mounting surfaces. Align the match-marks and reinstall the brake disc on the hub.
Page 517 Always On Parking brake. Brake fluid level. Vibration When Rear disc brakes. REFER to Section 100- Brakes Are Applied Front disc brakes. Brake Pedal Goes Brake fluid level. FILL the brake master Down Fast cylinder reservoir. BLEED the system. Air in system. BLEED the system.
Page 518 booster hose as necessary. Red Brake Warning Circuit. REFER to Section 413- Indicator Inoperative Bulb. Brake Noise Disc brake MACHINE or INSTALL a component. new brake component as necessary. REFER to Section 206-03 Section 206-04 Hydro-Boost, No Power steering Go To Pinpoint Test E Power Assist pump.
Page 519 Is the alignment OK? A3 CHECK THE DISC BRAKE COMPONENTS Check all disc brake calipers, anchor plate guide pins and GO to brake pads for binding, wear, damage, contamination and correct installation. REPAIR or INSTALL new components as necessary. RETEST for normal operation.
Page 520 cylinder reservoir. TEST the system for normal operation. Key in ON position. Does the brake warning indicator stay on? B2 CHECK PARKING BRAKE SWITCH Key in OFF position. GO to Disconnect: Parking Brake Switch. Key in ON position. Does the brake warning light stay on? INSTALL a new parking brake switch.
Page 521 REPAIR the ground short in circuit 128 (VT/YE). TEST the system for normal operation. Is the resistance greater than 10,000 ohms? B6 CHECK DAYTIME RUNNING LIGHTS (DRL) MODULE Disconnect: DRL Module C1030. REPAIR the DRL module. TEST Measure the resistance to ground at C124-2. the system for normal operation.
Page 522 INSTALL a new proportioning valve. 4481 kPa (510-650 psi)? RETEST for normal operation. PINPOINT TEST D: EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL Test Step Result / Action to Take D1 CHECK FOR SPONGY PEDAL Key in ON position. BLEED the brake system. REFER to Operate the brake pedal and note pedal feel.
Page 523 Check accessory drive belt tension and GO to condition. Refer to Section 303-05 Is the accessory drive belt OK? INSTALL a new accessory drive belt. REFER to Section 303-05 E3 CHECK POWER STEERING HOSES Check power steering pressure hoses, power GO to steering gear pressure hoses and power steering return hose for cracks or leaks.
Page 524 REMOVE connections between the power steering pump reservoir and obstructions or between the power steering pump reservoir and the hydro-boost INSTALL a new power brake booster. hose. Are there any obstructions? GO to F2 CHECK BOOSTER OPERATION Have an assistant check the fluid in the power steering pump System OK.
Page 525 Engine running at idle speed. GO to CAUTION: Do not hold the brake pedal at 444 Nm (100 lb) force for more than 5 seconds at a time. Apply brake pedal with approximately 444 Nm (100 lb) INSTALL a new hydro-boost force and hold.
Page 526 The function of the power brake booster check valve is to allow manifold vacuum to enter the power brake booster and prevent the escape of vacuum in case manifold vacuum is lost during sustained full throttle operation. To test the function of the power brake booster check valve : Start and run the engine for at least 10 seconds.
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 SECTION 206-00: Brake System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Bleeding —Components Special Tool(s) Worldwide Diagnostic System (WDS) 418-F224, New Generation STAR (NGS) Tester 418-F052, or equivalent scan tool NGS Flash Cable 418-F120 (007-00531) or Equivalent Master Cylinder Priming — In-Vehicle or Bench WARNING: Brake fluid contains polyglycol ethers and polyglycols.
Page 529 (2K478), and fill the brake master cylinder reservoir with High Performance DOT 3 Brake 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.
Page 530 7. Bleed each brake tube at the brake master cylinder as follows: 1. Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal. 2. Loosen the rear most brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting.
Page 531 Four Wheel Anti-Lock Brake System (4WABS) Hydraulic Control Unit (HCU) NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS) hydraulic control unit (HCU) has been installed new or if the HCU lines have been opened. 1.
Page 532 5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper (2B120) bleeder screw, and the LH front disc brake caliper bleeder screw, in that order. 6. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the dash, and follow the scan tool instructions.
Page 533 2. Have an assistant pump the brake pedal (BP) (2455) and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder 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.
Page 534 SECTION 206-00: Brake System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Bleeding —System Manual WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes.
Page 535 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out.
Page 536 11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw. Pressure 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2.
Page 537 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder 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.
Page 538 SECTION 206-00: Brake System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Hydraulic Leak Check 1. NOTE: Brake fluid is water soluble and it is possible that all evidence of fluid leakage has been washed off if the vehicle has been operated in the rain or snow.
Page 539 SECTION 206-00: Brake System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Runout Check —Brake Disc and Hub Special Tool(s) Brake Measurement Kit 134-R0199 or equivalent Material Item Specification High Temperature Nickel Anti- ESE-M12A4- Seize Lubricant F6AZ-9L494-AA CAUTION: The brake disc (1126) runout specification must be met to ensure correct brake performance without roughness complaints.
Page 540 7. If the total indicated runout exceeds the maximum specification, remove the brake disc. For additional information, refer to Section 206-03 for front or to Section 206-04 for rear. 8. Clean the brake disc mounting face of dirt, rust and foreign material. 9.
Page 541 13. If the brake disc TIR is still out of specification, measure and record the thickness of the brake disc. If thickness is sufficient to machine the brake disc to the runout specification, go to Step 14. If the thickness is not sufficient, install a new brake disc and recheck the TIR. 14.
Page 542 SECTION 206-03: Front Disc Brake 2003 Mustang Workshop Manual SPECIFICATIONS General Specifications Item Specification Disc brake lining wear limit 1.0 mm (0.040 in) 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)
Page 543: Front Disc Brake
SECTION 206-03: Front Disc Brake 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Front Disc Brake Front Disc Brake Components Item Part Number Description — Bleeder screw and bleeder screw cap assy 2N386 Caliper bolt 2B296 Guide pin 2A492 Guide pin boot...
Page 544 Item Part Number Description 2B120 Disc brake caliper 2L126 Bleeder screw cap 2208 Bleeder screw 2B164 Anti-rattle spring 2196 Caliper piston 2B115 Piston seal 2207 Piston dust boot 2L200 Pad slipper 2B292 Front disc brake caliper anchor plate 2001 Brake pads 2A492 Guide pin boot 2B296...
Page 545 is riveted to 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 SECTION 206-03: Front Disc Brake 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Pads Removal 1. Remove brake master cylinder filler cap (2162). Check brake fluid level in brake master cylinder reservoir (2K478). Remove fluid until brake master cylinder reservoir is half full.
Page 547 CAUTION: Do not pry in caliper sight hole to retract pistons as this can damage the pistons 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).
Page 548 8. Measure the front brake disc 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 10. Inspect the front disc brake anchor plate assembly. Check the guide pin boots for damage. Check the guide pins for binding and damage. Worn or damaged pins should be installed new. Installation CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining material.
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 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 553 SECTION 206-03: Front Disc Brake 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Brake Pads —Cobra Removal 1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full. 2. Raise and support the vehicle. For additional information, refer to Section 100-02 3.
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 10. Inspect the disc brake 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 SECTION 206-03: Front Disc Brake 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Caliper Removal 1. Raise and support 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 WARNING: Brake fluid contains polyglycol ethers and polyglycols.
Page 558 5. Lift the caliper off the anchor plate (2B292). 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 CAUTION: Make sure 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 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 SECTION 206-03: Front Disc Brake 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Brake Caliper —Cobra Removal 1. Raise and support the vehicle. For additional information, refer to Section 100-02 2. Remove the tire and wheel assembly. For additional information, refer to Section 204-04 3.
Page 562 7. 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 564 SECTION 206-03: Front Disc Brake 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Brake Caliper Anchor Plate —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.
Page 566 SECTION 206-03: Front Disc Brake 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Brake Caliper Anchor Plate Removal 1. Remove the pads. For additional information, refer to Pads in this section. 2. Remove the anchor plate (2B292). 1. Remove and discard the anchor plate bolts.
Page 568 3. If necessary, remove and discard the keeper nuts. 4. NOTE: If the brake disc cannot be easily removed, apply Rust 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.
Page 569 3. Align the match marks and 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 SECTION 206-03: Front Disc Brake 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Shield Removal 1. Remove the brake disc (1125). For additional information, refer to Disc in this section. 2. Remove the brake disc shield (2K004). 1. Drill out three brake disc shield rivets.
Page 572 SECTION 206-03: Front Disc Brake 2003 Mustang Workshop Manual DISASSEMBLY AND ASSEMBLY Caliper Disassembly 1. Remove the disc brake caliper (2B120). For additional information, refer to Caliper in this section. 2. Drain the remaining brake fluid from disc brake caliper.
Page 573 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 before assembly.
Page 574 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- 3. Install the caliper piston.
Page 575 1. Install the piston seal. 2. Install the piston boot on the piston. CAUTION: Be careful not to damage or dislodge the piston seal. Insert the caliper piston. CAUTION: Be careful not to cock the caliper piston. Press the caliper piston into the bore. 4.
Page 577 SECTION 206-04: Rear Disc Brake 2003 Mustang Workshop Manual SPECIFICATIONS General Specifications Item Specification Disc brake lining wear limit 1.0 mm (0.040 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 —...
Page 578: Rear Disc Brake
SECTION 206-04: Rear Disc Brake 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Rear Disc Brake WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes.
Page 580 SECTION 206-04: Rear Disc Brake 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Caliper Special Tool(s) Rear Caliper Piston Adjuster 206-026 (T87P-2588-A) Removal 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.
Page 581 6. Remove the rear disc brake caliper brake 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 583 SECTION 206-04: Rear Disc Brake 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Pads Special Tool(s) Rear Caliper Piston Adjuster 206-026 (T87P-2588-A) Removal 1. Use a suitable suction device to lower the brake fluid level in the master cylinder reservoir. 2. Raise and support the vehicle. For additional information, refer to Section 100-02 3.
Page 584 7. Remove the slippers. CAUTION: Use a hub-mount 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.
Page 585 CAUTION: Install the brake pads in full axle sets. Do not install new brake pads on only one side of vehicle. Install the new slipper and brake pads. 2. Position the caliper on the anchor plate and install the bolts. 3.
Page 586 7. Recheck the master cylinder fluid level.
Page 587 SECTION 206-04: Rear Disc Brake 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Disc Removal 1. Remove the 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.
Page 588 SECTION 206-04: Rear Disc Brake 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Brake Caliper Support Bracket Removal 1. Raise and support the vehicle. For additional information, refer to Section 100-02 2. Remove the tire and wheel assembly. For additional information, refer to...
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 SECTION 206-04: Rear Disc Brake 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Shield Removal 1. 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.
Page 592 SECTION 206-04: Rear Disc Brake 2003 Mustang Workshop Manual DISASSEMBLY AND ASSEMBLY Caliper Special Tool(s) Rear Caliper Piston Adjuster 206-026 (T87P-2588-A) Rear Caliper Spring Compressor Set 206-S027 (T87P-2588-B) Disassembly 1. Remove the rear disc brake caliper (2552). For additional information, refer to Caliper in the Removal and Installation portion of this section.
Page 593 5. Remove the rear disc brake piston and adjuster from the caliper bore. 6. Remove and discard the piston dust boot seal and piston seal from the caliper bore. CAUTION: The parking brake lever pin retainer clip (2A746) and spring cover are spring-loaded.
Page 594 8. Remove the following components: 1. spring cover 2. spring 3. washer 4. key plate 5. push rod 6. strut pin 7. push rod O-ring 9. Remove and discard the O-ring seal from the push rod. 10. Remove the parking brake lever (2A637). 1.
Page 595 NOTE: Use new brake fluid when assembling and bleeding the brake system. NOTE: 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 SECTION 206-05: Parking Brake and Actuation 2003 Mustang Workshop Manual SPECIFICATIONS Torque Specifications Description Nm Lb/Ft Parking brake control-to-cowl nut 17 Brake hose clip mounting bolt...
Page 597 SECTION 206-05: Parking Brake and Actuation 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Parking Brake Item Part Number Description 2780 Parking brake control 2552 Rear disc brake caliper The parking brake system is cable-actuated and controlled by an independent hand-operated parking brake control (2780).
Page 599 SECTION 206-05: Parking Brake and Actuation 2003 Mustang Workshop Manual DIAGNOSIS AND TESTING Parking Brake Inspection and Verification 1. Verify the customer's concern by operating the parking brake system to duplicate the condition. 2. Inspect to determine if one of the following mechanical or electrical concerns apply:...
Page 600 INSTALL a new parking brake cable as Section 100-02 necessary. TEST the system for normal Inspect for broken or binding parking operation. brake cables or broken guide clips. Is there a parking brake cable concern? GO to A2 CHECK THE PARKING BRAKE CONTROL Operate the parking brake control.
Page 602 SECTION 206-05: Parking Brake and Actuation 2003 Mustang Workshop Manual GENERAL PROCEDURES Parking Brake Cable Tension Release CAUTION: If any component in the parking brake system requires repair or if the rear axle housing (4010) is removed, the cable tension must be released.
Page 604: Parking Brake Control
SECTION 206-05: Parking Brake and Actuation 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Parking Brake Control Removal CAUTION: If any component in the parking brake system requires repair or if the rear axle housing (4010) is removed, the cable tension must be released.
Page 605 6. NOTE: Keep tension 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 607 SECTION 206-05: Parking Brake and Actuation 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Cable and Conduit —Front Removal CAUTION: If any component in the parking brake system requires repair or if the rear axle housing (4010) is removed, the cable tension must be released.
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 610 SECTION 206-05: Parking Brake and Actuation 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Cable and Conduit Removal NOTE: The RH rear is shown, the LH is similar. CAUTION: If any component in the parking brake system requires repair or if the rear axle housing (4010) is removed, the cable tension must be released.
Page 611 4. Remove the 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 614 SECTION 206-06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual SPECIFICATIONS Torque Specifications Description Nm lb-ft Brake master cylinder nuts Brake pedal bracket nuts Brake pedal bracket bolt Brake fluid control valve Hydraulic tube connections Brake fluid control valve bracket nut 14...
Page 615: Hydraulic Brake Actuation
SECTION 206-06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Hydraulic Brake Actuation Item Part Number Description 2K478 Master cylinder reservoir 2140 Master cylinder — Pedal support bracket (part of 2455) 2455 Brake pedal CAUTION: Blistering or swelling of rubber brake components may indicate contamination of the brake fluid by a petroleum based substance.
Page 616 Clean, fresh Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A is the only brake fluid that should be used in Ford vehicles. Do not reuse brake fluid drained or bled from the system.
Page 617 Brake Pressure Control Valve The brake pressure control valve proportions the pressure to the rear brakes. When the brake pedal is applied, brake fluid pressure passes through the proportioning valves to the rear brake system until the valve split point is reached. Above its split point, the proportioning valve begins to reduce the hydraulic pressure to the rear brakes, creating a balanced braking condition between the front and rear brakes.
Page 618 SECTION 206-06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Pedal and Bracket Removal 1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414- 2. Remove the stoplight switch retaining pin. 3. Slide the stoplight switch (13480) and booster push rod from the brake pedal pin.
Page 619 6. Remove the brake pedal and bracket. Installation 1. To install, reverse the removal procedure.
Page 621: Master Cylinder
SECTION 206-06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Master Cylinder 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).
Page 623 SECTION 206-06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Master Cylinder —Hydro-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).
Page 624 Installation 1. To install, reverse the removal procedure. Bleed the brake system. For additional information, refer to Section 206-00...
Page 626 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 until it is fully seated.
Page 628: Control Valve
SECTION 206-06: Hydraulic Brake Actuation 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION 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.
Page 630 SECTION 206-07: Power Brake Actuation 2003 Mustang Workshop Manual SPECIFICATIONS Torque Specifications Description Nm lb-ft Power brake booster nuts Brake master cylinder nuts Hydraulic tube connections Power steering pressure lines 19...
Page 631: Power Brake Booster
SECTION 206-07: Power Brake Actuation 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Brake Booster —Vacuum Power Brake Booster Item Part Number Description 2140 Master cylinder 2B560 Hydro-Boost 2005 Power brake booster The vacuum type power brake booster (2005): is a dual diaphragm, vacuum assisted power brake booster reduces brake pedal force and travel distance.
Page 632 is located on the front of the power brake booster. is installed separately; (install a new grommet when installing a new check valve). is positioned 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.
Page 633 SECTION 206-07: Power Brake Actuation 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Brake Booster —Hydro-Boost The Hydro-Boost brake booster is a hydraulically operated brake booster powered by the power steering pump (3A674). The power steering pump provides the fluid pressure to operate both the power brake booster and the power steering gear (3504).
Page 635 SECTION 206-07: Power Brake Actuation 2003 Mustang Workshop Manual GENERAL PROCEDURES Hydro-Boost Bleeding 1. NOTE: The Hydro-Boost power brake booster (2B560) is generally self-bleeding, and the following procedure will normally bleed the air from the power brake booster. Normal operation of the vehicle will further remove any additional trapped air.
Page 637 SECTION 206-07: Power Brake Actuation 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Brake Booster —Vacuum Removal 1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414- 2. Remove the air cleaner housing. For additional information, refer to Section 303-12 3.
Page 638 7. Remove the 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 640 SECTION 206-07: Power Brake Actuation 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Brake Booster —Hydro-Boost Special Tool(s) Installer Set, Teflon Seal 211-D027 (D90P-3517-A) or equivalent Removal WARNING: The power brake booster should not be carried by the accumulator, nor should it ever be dropped on the accumulator. Check the snap ring on the accumulator for correct seating before the power brake booster is used.
Page 641 5. Disconnect 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 9. Remove the 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 645 SECTION 206-09A: Anti-Lock Control — Rear 2003 Mustang Workshop Manual SPECIFICATIONS Torque Specifications Description Nm lb-ft lb-in Anti-lock brake control module screws — Brake line fittings to hydraulic control unit — Front anti-lock brake sensor bolt — Hydraulic control unit to mounting bracket nuts 18 —...
Page 646 SECTION 206-09A: Anti-Lock Control — Rear 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Anti-Lock Control The four wheel anti-lock brake system (4WABS) consists of the following components: anti-lock brake control module (2C346) front anti-lock brake sensor (2C205) front anti-lock brake sensor indicator (2C182)
Page 647 SECTION 206-09A: Anti-Lock Control — Rear 2003 Mustang Workshop Manual DIAGNOSIS AND TESTING Anti-Lock Control Refer to Wiring Diagrams Cell , Anti-Lock Brake for schematic and connector information. Special Tool(s) Worldwide Diagnostic System (WDS) 418-F224, New Generation STAR (NGS) Tester...
Page 648 Visual Inspection Chart Mechanical Electrical Low brake fluid Central junction box (CJB)Fuse: Anti-lock brake sensor 15 (10A) Anti-lock brake sensor indicator 29 (15A) Base brake system 33 (15A) 35 (15A) Battery junction box (BJB) Fuse: ABS 1 (50A) ABS 2 (20A) Circuitry Damaged or corroded connectors Yellow ABS warning indicator...
Page 649 B1596 Repair Continuous Codes REPAIR the DTCs retrieved. C1095 ABS Hydraulic Pump Motor Go To Pinpoint Test E Circuit Failure C1145 RF Anti-Lock Brake Sensor Go To Pinpoint Test F Input Circuit Failure C1155 LF Anti-Lock Brake Sensor Go To Pinpoint Test F Input Circuit Failure C1165 RR Anti-Lock Brake Sensor...
Page 650 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 ABSR_I Rear ABS Inlet Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-...
Page 651 warning indicator system. Test K Base brake REFER to system. Section 206- Poor vehicle tracking during Air in the brake Go To Pinpoint anti-lock function system. Test L Hydraulic control REFER to unit (HCU). Section 206- Base brake system. Pinpoint Tests PINPOINT TEST A: NO COMMUNICATION WITH THE ANTI-LOCK BRAKE CONTROL MODULE Result / Action to...
Page 652 PINPOINT TEST B: UNABLE TO ENTER 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 INSTALL a new anti-lock brake control brake control module. module; REFER to Module .
Page 653 Measure the resistance between anti-lock brake control module INSTALL a new C135 Pin 12, Circuit 1205 (BK), harness side and ground; and anti-lock brake between anti-lock brake control module C135 Pin 15, Circuit 397 control module; (BK/WH), harness side and ground. REFER to Module REPEAT the self-...
Page 654 E1 CHECK THE PUMP MOTOR FOR CONTINUOUS OPERATION Check the pump motor for continuous operation. INSTALL a new Is the pump motor running continuously? anti-lock brake control module; REFER to Module REPEAT the self- test. GO to E2 CHECK CIRCUIT 534 (YE/LG) FOR AN OPEN Key in OFF position.
Page 655 the self-test. Does the pump motor operate? PINPOINT TEST F: DTC C1145 (RF), C1155 (LF), C1165 (RR), C1175 (LR), ANTI-LOCK BRAKE SENSOR INPUT CIRCUIT FAILURE Test Step Result / Action to Take F1 CHECK THE SUSPECT ANTI-LOCK BRAKE SENSOR CIRCUIT FOR SHORT TO POWER Key in OFF position.
Page 656 control module C135 Pins, harness side and ground as follows: GO to Anti-Lock Brake Control Module C135 Pin Circuit C1145 (RF) (YE/RD) C1155 (LF) (TN/OG) C1165 (RR) (TN/LG) C1175 496 (OG) (LR) Is the resistance greater than 10,000 ohms? F3 CHECK THE SUSPECT ANTI-LOCK BRAKE SENSOR FOR A SHORT TO GROUND Disconnect: Suspect Anti-Lock Brake Sensor.
Page 657 test. Anti-Lock Anti-Lock Brake Control Brake Module Sensor Circuit C1145 C135 Pin 4 C160 Pin 1 (RF) (YE/RD) C1145 C135 Pin 5 C160 Pin 2 (RF) (YE/BK) C1155 C135 Pin 20 C150 Pin 1 (LF) (TN/OG) C1155 C135 Pin 21 C150 Pin 2 (LF) (TN/BK)
Page 658 Test Step Result / Action to Take G1 CHECK THE VEHICLE COMPONENTS Check for correct wheel and tire GO to size, front-to-rear and side-to- side. Check for excessive bearing REPAIR as necessary. CLEAR the DTCs. REPEAT the end play. self-test. Check the anti-lock brake sensor indicator for a deformation or missing teeth.
Page 659 Have an assistant monitor the anti-lock brake INSTALL a new anti-lock brake control module PIDs LF_WSPD, RF_WSPD, sensor; REFER to Sensor—Front LR_WSPD, and RR_WSPD while driving at Sensor—Rear . CLEAR the DTCs. various speeds. REPEAT the self-test. NOTE: The vehicle must be driven 16 km/h (10 miles) during this test step.
Page 660 REPAIR the circuit. CLEAR the DTCs. REPEAT the self- test. Is the resistance less than 5 ohms? PINPOINT TEST J: THE YELLOW ABS WARNING INDICATOR DOES NOT SELF-CHECK Test Step Result / Action to Take J1 CHECK THE ABS WARNING INDICATOR CIRCUITRY Key in OFF position.
Page 661 FUNCTION Test Step Result / Action to Take L1 BLEED THE BRAKE SYSTEM Bleed the brake system. Refer to Section GO to 206-00 Check for vehicle tracking poorly. Does the vehicle track poorly? The brake system is OK. TEST the system for normal operation.
Page 662 Hydraulic Control Unit . TEST the system two seconds. for normal operation. Trigger the anti-lock brake control module active command PMP MOTOR ON for four seconds. GO to Apply moderate brake pedal effort. Have an assistant attempt to rotate the LR and RR wheels while the pump motor is running.
Page 663 SECTION 206-09A: Anti-Lock Control — Rear 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Sensor Indicator —Rear 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) Removal 1. Remove the rear axle shaft bearing, refer to...
Page 664 Installation 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 SECTION 206-09A: Anti-Lock Control — Rear 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Hydraulic Control Unit Removal 1. Disconnect the battery ground cable(14301). 2. Disconnect the anti-lock-brake control module electrical connector. 3. NOTE: The 4 wheel anti-lock brake system (4WABS) with traction control is shown , the 4WABS without traction control system is similar with one less hydraulic line.
Page 667 6. Remove the pump motor electrical connector. 7. Remove 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 669 SECTION 206-09A: Anti-Lock Control — Rear 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Module Removal 1. Remove the hydraulic control unit (HCU). Refer to Hydraulic Control Unit 2. Remove the pump motor electrical connector. 3. Remove the anti-lock-brake control module screws.
Page 671 SECTION 206-09A: Anti-Lock Control — Rear 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Sensor —Front Removal 1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04 2. Remove the inner fender splash shield. 1. Remove the inner fender splash shield push pins.
Page 672 Installation 1. To install, reverse the removal procedure.
Page 674 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.
Page 675 2. Remove the rear 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 SECTION 206-09B: Anti-Lock Control — Traction Control 2003 Mustang Workshop Manual SPECIFICATIONS Torque Specifications Description Nm lb-ft lb-in Anti-lock brake control module screws — Brake line fittings to hydraulic control unit — Front anti-lock brake sensor bolt — Hydraulic control unit to mounting bracket nuts 18 —...
Page 677 SECTION 206-09B: Anti-Lock Control — Traction Control 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Anti-Lock Control —Traction Control The four wheel anti-lock brake system (4WABS) with traction control consists of the following components: anti-lock brake control module (2C346) front anti-lock brake sensor (2C204)/(2C205)
Page 678 SECTION 206-09B: Anti-Lock Control — Traction Control 2003 Mustang Workshop Manual DIAGNOSIS AND TESTING Anti-Lock Control —Traction Control Refer to Wiring Diagrams Cell , Anti-Lock Brake System for schematic and connector information. Special Tool(s) Worldwide Diagnostic System (WDS) 418-F224, New Generation STAR (NGS)
Page 679 Inspection and Verification 1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical and electrical damage. Visual Inspection Chart Mechanical Electrical Low brake fluid Central junction box (CJB) Fuse: Anti-lock brake sensor 5 (15A) Anti-lock brake sensor indicator 15 (10A) Base brake system...
Page 680 Anti-Lock Brake Control Module Diagnostic Trouble Code (DTC) Index Description Source Action B1318 Battery Voltage Low ABS/TC Go To Pinpoint Test C B1342 ECU Is Defective ABS/TC INSTALL a new anti-lock brake control module; REFER to Module . REPEAT the self-test.
Page 681: Table Of Contents
Anti-Lock Brake Control Module Parameter Identification (PID) Index Anti-Lock Brake Control Module Parameter Identification (PID) Index Description Expected Value CCNTABS Number of Continuous DTCS in one count per bit the Anti-Lock Brake Control Module BOO_ABS Brake Switch Input OFF, ON PMP_MTR ABS Pump Motor OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF-...
Page 682 Valve RF_TC_S RF Traction Control Switching OFF, ON Valve LR_TC_S LR Traction Control Switching OFF, ON Valve RR_TC_S RR Traction Control Switching OFF, ON Valve T/ALVAL Left Traction Control Valve OFF---, OFFO--, OFF-B-, OFF--G, OFFO-G, OFF- Output State BG, OFFOBG, ON---, ONO--, ON-B-, ON--G, ONO- G, ON-BG, ONOBG T/ARVAL Right Traction Control Valve...
Page 683 test. Condition Possible Sources Action No communication with the anti- CJB Fuse 29 Go To Pinpoint lock brake control module (15A). Test A Circuitry. Anti-lock brake control module. Unable to enter self-test Anti-lock brake Go To Pinpoint control module. Test B The yellow ABS warning indicator Circuitry.
Page 684 REPEAT the self- test. Is the voltage greater than 10 volts? A2 CHECK THE ANTI-LOCK BRAKE CONTROL MODULE GROUNDS Measure the resistance between anti-lock brake control module INSTALL a new C141 Pin 12, Circuit 1205 (BK), harness side and ground; and anti-lock brake between anti-lock brake control module C141 Pin 15, Circuit 397 control module;...
Page 685 414-00 Is the battery voltage between 10 and 13 volts with KOEO, and between 11 and 17 volts with the engine running? C2 CHECK THE VOLTAGE TO THE ANTI-LOCK BRAKE CONTROL MODULE Key in OFF position. GO to Disconnect: Anti-Lock Brake Control Module C141. Key in ON position.
Page 686 Depress the brake pedal while checking the stoplamps. GO to Do the stop lamps illuminate? REFER to Section 417- D2 CHECK THE BRAKE PEDAL INPUT TO THE ANTI-LOCK BRAKE CONTROL MODULE Key in OFF position. INSTALL a new anti-lock Disconnect: Anti-Lock Brake Control Module C141. brake control module;...
Page 687 Is the voltage greater than 10 volts? E3 CHECK CIRCUIT 1205 (BK) FOR AN OPEN Measure the resistance between anti-lock brake control module GO to C141 Pin 12, Circuit 1205 (BK), harness side and ground. REPAIR the circuit. CLEAR the DTCs. REPEAT the self- test.
Page 688 test. Measure the voltage between anti-lock brake control module C141 Pins, harness side and ground as follows: GO to Anti-Lock Brake Control Module C141 Pin Circuit C1145 (RF) (YE/RD) C1155 (LF) (TN/OG) C1165 (RR) (TN/LG) C1175 496 (OG) (LR) Is any voltage present? F2 CHECK THE SUSPECT ANTI-LOCK BRAKE SENSOR CIRCUIT FOR SHORT TO GROUND Key in OFF position.
Page 689 Is the resistance greater than 10,000 ohms? F3 CHECK THE SUSPECT ANTI-LOCK BRAKE SENSOR FOR A SHORT TO GROUND Disconnect: Suspect Anti-Lock Brake Sensor. If RF, REPAIR Circuit 514 (YE/RD) Measure the resistance between suspect anti-lock and Circuit 516 (YE/BK), as brake sensor Pin 1 (component side) and ground.
Page 690 (RR) C1175 C141 Pin 22 C320 Pin 2 496 (OG) (LR) C1175 C141 Pin 23 C320 Pin 1 (LR) (GY/BK) Are the resistances less than 5 ohms? F5 CHECK THE ANTI-LOCK BRAKE SENSOR Measure the resistance between suspect anti-lock INSTALL a new anti-lock brake brake sensor pin 1 (component side) and suspect control module;...
Page 691 INSTALL a new anti-lock brake control module; mode on the diagnostic tool: REFER to Module . REPEAT the self-test. CLEAR the DTCs. Key in OFF position. Key in ON position. If another DTC is retrieved, GO to the Anti-Lock Brake Test drive the vehicle over 24 Control Module Diagnostic Trouble Code (DTC) index.
Page 692 Test Step Result / Action to Take I1 CHECK THE ABS WARNING INDICATOR CIRCUITRY Key in OFF position. INSTALL a new anti-lock brake Disconnect: Anti-Lock Brake Control Module C141. control module; REFER to Key in ON position. Module . TEST the system for Depress and release the shorting bar connector normal operation.
Page 693 GO to Trigger the anti-lock brake control module active command PMP MOTOR ON for four seconds. Apply moderate brake pedal effort. Have an assistant attempt to rotate the LF wheel while the pump motor is running. Does the LF wheel rotate? K3 CHECK THE LF ABS VALVE RELEASE Apply moderate brake pedal effort.
Page 694 K8 CHECK THE RR ABS VALVE OPERATION NOTE: Trigger must be depressed twice. INSTALL a new HCU; REFER to Each depress runs the pump motor for two Hydraulic Control Unit . TEST the system seconds. for normal operation. Trigger the anti-lock brake control module active command PMP MOTOR ON for four seconds.
Page 695 L2 CHECK CIRCUIT 959 (GY) FOR AN OPEN Key in OFF position. GO to Disconnect: Traction Control Switch C239. Measure the resistance between instrument cluster C251 Pin 9, Circuit 959 (GY), harness side and traction control switch C239 REPAIR the circuit. Pin 4, Circuit 959 (GY), harness side.
Page 696 Is the resistance less than 5 ohms between the instrument cluster and traction control switch and greater than 10,000 ohms between instrument cluster and ground? M2 CHECK CIRCUIT 489 (PK/BK) FOR AN OPEN Key in ON position. GO to Measure the voltage between traction control switch C239 Pin 3, Circuit 489 (PK/BK), harness side and ground.
Page 698 SECTION 206-09B: Anti-Lock Control — Traction Control 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Sensor Indicator —Rear 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) Removal 1. Remove the rear axle shaft bearing, refer to...
Page 699 Installation 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 SECTION 206-09B: Anti-Lock Control — Traction Control 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Hydraulic Control Unit Removal 1. Disconnect the battery ground cable(14301). 2. Disconnect the anti-lock-brake control module electrical connector. 3. NOTE: The 4 wheel anti-lock brake system (4WABS) with traction control is shown , the 4WABS without traction control system is similar with one less hydraulic line.
Page 702 6. Remove the pump motor electrical connector. 7. Remove 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 704 SECTION 206-09B: Anti-Lock Control — Traction Control 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Module Removal 1. Remove the hydraulic control unit (HCU). Refer to Hydraulic Control Unit 2. Remove the pump motor electrical connector. 3. Remove the anti-lock-brake control module screws.
Page 706 SECTION 206-09B: Anti-Lock Control — Traction Control 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Sensor —Front Removal 1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04 2. Remove the inner fender splash shield. 1. Remove the inner fender splash shield push pins.
Page 707 Installation 1. To install, reverse the removal procedure.
Page 709 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.
Page 710 2. Remove the rear 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 SECTION 206-09B: Anti-Lock Control — Traction Control 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Switch —Traction Control Removal and Installation 1. NOTE: If the vehicle is equipped with an automatic transmission, position the shift lever in the 1 position before detaching the floor console finish panel.
Page 712 5. To install, reverse the removal procedure.
Page 713 SECTION 211-00: Steering System — General Information 2003 Mustang Workshop Manual SPECIFICATIONS General Specifications Item Specification Lubricants Motorcraft MERCON® Multi-Purpose (ATF) Transmission Fluid XT- MERCON® 2-QDX Power Steering Gear Turning effort 2.27 Kg (5.0 lb) Turns lock-to-lock 2.38 Power Steering Purge Vacuum...
Page 714 Relief pressure 8,274-9,510 kPa (1,200-1,380 psi)
Page 715 SECTION 211-00: Steering System — General Information 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Steering System The steering system has a typical rack-and-pinion design consisting of the following: Steering System Components — 3.8L Engine (CII Power Steering Pump) Item Part Number...
Page 716 Item Part Number Description 3A713 Power steering hose 3R700 Power steering pump reservoir 3A714 Power steering hose 2B559 Hydro-boost assy 3E525 Power steering hose 3504 Steering gear 3A130 Tie-rod end 3A713 Power steering hose 3D746 Power steering fluid cooler 3A674 Power steering pump For information on the power steering oil reservoir (3A697), refer to Section 211-02...
Page 718 SECTION 211-00: Steering System — General Information 2003 Mustang Workshop Manual DIAGNOSIS AND TESTING Steering System 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...
Page 719 1. Verify the customer concern by operating the steering system. 2. Inspect Tires Check the tire pressure. Refer to the Vehicle Certification (VC) label. Verify that all tires are sized to specification. Check the tires for damage or uneven wear. 3.
Page 720 6. External Leak Check With the ignition switch at OFF, wipe off the power steering pump, power steering hoses, power steering fluid cooler (3D746) and steering gear (3504). With the engine running, turn the steering wheel from stop-to-stop several times. Do not hold steering wheel at stops.
Page 721 Visual Inspection Chart Mechanical Loose tie-rod ends Loose suspension components Loose steering column shaft universal joints Loose column intermediate shaft bolts Steering gear Binding or misaligned steering column Power steering pump Bent or pinched power steering hoses 9. If an obvious cause for an observed or reported malfunction is found, correct the cause (if possible) before proceeding to the next step.
Page 722 Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a turn or the steering correction is completed. Shimmy Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements.
Page 723 column bearing(s). bearing(s). REFER to Section 211-04 Loose, worn or INSTALL a new lower damaged lower steering column shaft. steering column shaft REFER to Section U-joint(s). 211-04 Wander Unevenly loaded or INFORM the overloaded vehicle. customer of incorrect vehicle loading. Loose, worn or GO to the Tie-Rod damaged front wheel...
Page 724 operation. Incorrect CORRECT as frame/underbody required. REFER to alignment. Frame Dimension Manual. Feedback Loose, worn or GO to the Tie-Rod damaged front wheel Articulation Torque spindle tie-rod. Component Test. Loose, worn or GO to the Steering damaged tie-rod ends. Linkage Component Test.
Page 725 Component Tests Steering Linkage 1. NOTE: Excessive vertical motion of the studs relative to the sockets may indicate excessive wear. With the parking brake applied, perform the following: Have an assistant rotate the steering wheel back and forth 360 degrees and watch for relative motion of the studs in the tie-rod end ball sockets.
Page 726 On some vehicles, the power steering pump high pressure port is inaccessible and the special tool should then be installed either at the steering gear or at a point in the high pressure line between the power steering pump and the steering gear. 2.
Page 727 11. Turn (or have an assistant turn) the steering wheel slightly in both directions and release quickly while watching the pressure gauge. The pressure reading should move from the normal back pressure reading and snap back as the steering wheel is released. If the pressure returns slowly or sticks, the rotary valve in the steering gear is sticking or the steering column is binding.
Page 729 SECTION 211-00: Steering System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES System Flushing —CII Power Steering Pump WARNING: Do not mix oil types. Any mixture or any unapproved oil can lead to seal deterioration and leaks. A leak can ultimately cause loss of fluid, which can result in a loss of power steering assist.
Page 730 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. 10. Install the fuel pump fuse. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time.
Page 731 SECTION 211-00: Steering System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES System Flushing —CIII Power Steering Pump WARNING: Do not mix oil types. Any mixture or any unapproved oil can lead to seal deterioration and leaks. A leak can ultimately cause loss of fluid, which can result in a loss of power steering assist.
Page 732 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. 10. Install the fuel pump fuse. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time.
Page 733 SECTION 211-00: Steering System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Purging —CII Power Steering Pump Special Tool(s) Vacuum Pump 416-D002 (D95L-7559-A) or Equivalent CAUTION: If the air is not purged from the power steering system correctly, premature power steering pump failure can result.
Page 734 5. Release the vacuum and remove the special tool. 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 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. Cycle the steering wheel fully to the left and right every 30 seconds for approximately five minutes.
Page 736 SECTION 211-00: Steering System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Purging —CIII Power Steering Pump Special Tool(s) Vacuum Pump 416-D002 (D95L-7559-A) or Equivalent CAUTION: If the air is not purged from the power steering system correctly, premature power steering pump failure can result.
Page 737 5. Release the vacuum and remove the special tool. 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 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. Cycle the steering wheel fully to the left and right every 30 seconds for approximately five minutes.
Page 739 SECTION 211-00: Steering System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Fill WARNING: Do not mix oil types, any mixture or any unapproved oil can lead to seal deterioration and leaks. A leak can ultimately cause loss of fluid, which can result in a loss of power steering assist.
Page 741 SECTION 211-02: Power Steering 2003 Mustang Workshop Manual SPECIFICATIONS General Specifications Item Specification Lubricants Motorcraft Multi-Purpose (ATF) Transmission Fluid XT-2-QDX MERCON® Silicone Dielectric Compound D7AZ-19A331-A ESE-M1C171-A Steering Gear Grease C3AZ-19578-A ESW-M1C87-A Torque Specifications Description Nm lb-ft lb-in Front wheel spindle tie-rod —...
Page 743: Power Steering
SECTION 211-02: Power Steering 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Power Steering System View Steering System Components — 3.8L Engine Item Part Number Description 3A714 Power steering hose 3A674 Power steering pump 3493 Power steering hose 3504 Steering gear...
Page 744 Item Part Number Description 3A713 Power steering return hose 3R700 Power steering pump reservoir 3A714 Power steering hose — Hydroboost unit 3E525 Power steering reservoir pump hose 3504 Steering gear 3289 Tie-rod end 3A713 Power steering return hose 3D746 Power steering fluid cooler 3A674 Power steering pump Steering Gear Mounting...
Page 745 Item Part Number Description 3E552 Steering gear mounting bracket (2 req'd) N803736- Bolt (2 req'd) S192 72044-S36 Cotter pin (2 req'd) 385002-S2 Nut (2 req'd) 3289 Tie-rod end (2 req'd) 385032-S2 Nut (2 req'd) 3504 Steering gear N803734-S2 Washer (2 req'd) N620483-S60 Nut (2 req'd) 3F640 Steering gear mounting bracket housing...
Page 746 — To left turn port — To right turn port — Return port (out) — Pressure port (in) — Oil flow — right turn — Air transfer tube (between bellows) Power Steering Pump — CII Power Steering Pump — CIII Power Steering Gear Identification CAUTION: Always use the ID code when ordering service parts.
Page 747 Item Part Number Description — Steering gear housing — Mounting boss — Shift code — Day code — Month code — Build year — Steering gear model code Power Steering Pump Identification CAUTION: Always use the ID code when ordering service parts. The pump identification code is located on a tag attached to the power steering pump.
Page 749 SECTION 211-02: Power Steering 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Reservoir —CIII Pump Removal 1. Remove the bolts. 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...
Page 751 SECTION 211-02: Power Steering 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Pump —CII Special Tool(s) Teflon Seal Replacer Set 211D027 (D90P-3517-A) or equivalent Removal and Installation 1. Disconnect the power steering hose. Remove and discard the seal ring. 2. Disconnect the power steering hose.
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-...
Page 754 SECTION 211-02: Power Steering 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Pump —CIII Special Tool(s) Teflon Seal Replacer Set 211-D027 (D90P-3517-A) or equivalent Removal and Installation 1. Remove the pulley. For additional information, refer to Pulley—CIII Pump in this section.
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-...
Page 757 SECTION 211-02: Power Steering 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Pulley —CII Pump Special Tool(s) Pump Pulley Installer 211-009 (T65P-3A733-C) Pump Pulley Remover 211-016 (T69L-10300-B) Removal 1. Remove the drive belt. For additional information, refer to Section 303-05 2. Using the special tool, remove the pulley.
Page 758 2. Install the drive belt. For additional information, refer to Section 303-05...
Page 759 SECTION 211-02: Power Steering 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Pulley —CIII Pump Special Tool(s) Pump Pulley Replacer 211-185 (T91P-3A733-A) Pump Pulley Remover 211-016 (T69L-10300-B) Removal 1. Remove the drive belt. For additional information, refer to Section 303-05 2. Raise and support the vehicle. For additional information, refer to Section 100-02 3.
Page 760 2. Install the drive belt. For additional information, refer to Section 303-05 3. Lower the vehicle.
Page 761 SECTION 211-02: Power Steering 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Hose Special Tool(s) Installer Set, Teflon Seal 211-D027 (D90P-3517-A) or equivalent Removal and Installation CAUTION: While servicing the power steering system, make sure to plug all open hoses, line fittings, and fluid ports to prevent the entry of contaminants or premature failure of the power steering components can result.
Page 763 SECTION 211-02: Power Steering 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Cooler —Fluid Removal 1. Raise and support the vehicle. For additional information, refer to Section 100-02 2. Disconnect the power steering hoses. 3. Remove the bolt and routing bracket.
Page 765 SECTION 211-02: Power Steering 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Gear Special Tool(s) Teflon Seal Replacer Set 211-D027 (D90P-3517-A) or Equivalent Tie Rod End Remover 211-001 (TOOL-3290-D) Removal 1. Turn the steering wheel as necessary to position the wheels in the straight-ahead position. Do not lock the steering column.
Page 766 6. Rotate the steering column intermediate shaft as necessary to access the pinch bolt. Remove and discard the pinch bolt. 7. Lower the vehicle. 8. Turn the steering wheel back to the straight-ahead position. Turn the ignition key to the locked position.
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-...
Page 769 SECTION 211-02: Power Steering 2003 Mustang Workshop Manual DISASSEMBLY AND ASSEMBLY Gear 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-B) or Equivalent Material Item...
Page 770 2. Install the steering gear into the special tools. 3. Clean the exterior of the steering gear with solvent. If necessary, drain any excess power steering fluid. 4. Inspect the steering gear housing for cracks and other damage. If necessary, install a new steering gear.
Page 771 CAUTION: Place the steering gear at the center position. Use a crowfoot on the flat of the rack gear to resist rotation and prevent damage to the steering gear during removal and installation of the front wheel spindle tie-rods. Place the steering gear at the center position. Install a crowfoot on the flat of the steering gear. Using the special tool remove the front wheel spindle tie-rods.
Page 772 CAUTION: Place the steering gear at the center position. Use a crowfoot on the flat of the rack gear to resist rotation and prevent damage to the steering gear during removal and installation of the front wheel spindle tie-rods. Place the steering gear at the center position. Install a crowfoot on the flat of the steering gear. Using the special tool install the front wheel spindle tie-rods.
Page 773 6. Install the nut and the tie-rods ends. Align the marks. Apply silicone dielectric compound to the front wheel spindle tie-rod threads. 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.
Page 775 SECTION 211-04: Steering Column 2003 Mustang Workshop Manual SPECIFICATIONS General Specifications Item Specification Lubricant Ignition Lock Grease FOAZ-19584-A ESA-M1C232-A Torque Specifications Description Nm lb-ft lb-in Lock cylinder housing screws — Steering column lower bearing retainer bolts — Ignition switch screws —...
Page 776 SECTION 211-04: Steering Column 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Steering Column Item Part Number Description 043B13 Driver air bag module N804385-S100 Steering wheel bolt 3600 Steering wheel...
Page 777 N805572-S36 Air bag module retaining screws (2 req'd) 3L518 Steering wheel spoke cover (2 req'd) — Lock tabs 14A664 Clockspring 13318 Turn indicator cancel cam 3C610 Snap ring 3520 Bearing spring 3518 Upper bearing sleeve 3517 Upper bearing (small) 3517 Lower bearing (large) 3524 Shaft assembly...
Page 778 N621906 N803942 Bolt 3A525 Intermediate shaft coupling 11A128 Ignition key warning switch terminal N806583 Bearing housing retaining screw N804865-S58 Screw 14A06 Wire connector bracket 3E715 Lock lever lower actuator 3E691 Lock pawl 3F723 Actuator housing 3E745 Lock actuator cover 3F719 Ignition/shifter interlock cable N808124-58M Screw...
Page 780 SECTION 211-04: Steering Column 2003 Mustang Workshop Manual GENERAL PROCEDURES Supplemental Restraint System (SRS) Deactivation and Reactivation Special Tool(s) Diagnostic Tool, Restraint System (2 Req'd) 418-F088 (105-R0012) Deactivation WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module.
Page 781 Disconnect the battery ground cable and wait at least one minute. For additional information, refer to Section 414-01 2. Remove the steering column opening lower finish panel. 1. Remove the screws. 2. Pull out to release the retaining clips and remove the steering column opening lower finish panel.
Page 782 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. 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.
Page 783 10. Connect the battery ground cable. For additional information, refer to Section 414-01 11. With the restraint system diagnostic tools installed at all deployable devices, prove out the supplemental restraint system (SRS). For additional information, refer to Section 501-20B 12. Disconnect the battery ground cable and wait at least one minute. For additional information, refer to Section 414-01 Reactivation...
Page 784 4. Install the right hand A/C register duct. 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.
Page 785 10. Connect the battery ground cable. For additional information, refer to Section 414-01 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.
Page 786 SECTION 211-04: Steering Column 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Ignition Switch Lock Cylinder —Functional Removal and Installation 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01 2. Remove the ignition switch lock cylinder (11582).
Page 788 SECTION 211-04: Steering Column 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Ignition Switch Lock Cylinder —Non-Functional Removal and Installation 1. NOTE: Make sure the front wheels are in the straight-ahead position. Disconnect the battery ground cable (14301) and wait at least one minute to allow the depletion of the restraint system backup power supply.
Page 789 Remove the ignition switch lock cylinder. Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. Use a 3/8-inch drill bit to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. Remove and discard the ignition switch lock cylinder and clean the drill shavings from the steering column.
Page 790 WARNING: To avoid the risk of serious personal injury, 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 SECTION 211-04: Steering Column 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Wheel Removal and Installation 1. Disconnect the battery ground cable (14301) and wait at least one minute to allow the depletion of the restraint system backup power supply. For additional information, refer to Section 414- 2.
Page 792 7. Remove the steering wheel while routing the wires from the clockspring through the steering wheel. 8. To install, reverse the removal procedure. 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).
Page 793 SECTION 211-04: Steering Column 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Column Removal and Installation All vehicles 1. Disconnect the battery ground cable and wait at least one minute to allow the depletion of the restraint system backup power supply. For additional information, refer to...
Page 794 6. Remove the pinch bolt and disconnect the coupling from 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 10. Disconnect the ignition/shifter interlock and remove the steering column. All vehicles 11. To install, reverse the removal procedure. 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).
Page 797 SECTION 211-04: Steering Column 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Steering Column Shaft Removal and Installation CAUTION: Do not allow the steering column shaft to rotate while intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the steering column shaft has rotated the clockspring must be removed and recentered.
Page 798 5. To install, reverse the removal procedure.
Page 799 SECTION 211-04: Steering Column 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Coupling Removal and Installation CAUTION: Do not allow the steering column shaft to rotate while intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the steering column shaft has rotated the clockspring must be removed and recentered.
Page 801 SECTION 211-04: Steering Column 2003 Mustang Workshop Manual DISASSEMBLY AND ASSEMBLY Steering Column Special Tool(s) Steering Column Locking Lever Tool (Shop Fabricated) Disassembly WARNING: To avoid risk of serious personal injury, follow all warnings, cautions, notes and instructions in the driver air bag removal and installation procedure.
Page 802 4. Remove 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 8. Remove the two tilt pivot screws. WARNING: Steering column position spring is 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.
Page 804 11. Remove the snap ring. 12. Remove the upper bearing spring (3520). 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 15. Using a suitable punch, remove the lower bearing (3517) from the lock cylinder housing. 16. Use 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.
Page 806 20. Remove 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 24. NOTE: 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 3. Install the lock actuator lever return spring. 4. Install the ignition lock cylinder lockout lever. 5. NOTE: The lock lever with two teeth is installed on the left-hand 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.
Page 809 6. Install the lock lever actuators. 1. Lubricate the lock lever actuator with Ignition 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.
Page 810 Install the lower bearing and sleeve. Item Part Number Description — Outer race 3517 Bearing (in the "UP" position) — Ball — Inner race CAUTION: Install the steering 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.
Page 811 Item Part Number Description — Outer race — Bearing (in the "UP" position) — Ball — Inner race CAUTION: Install the steering column bearing so that the inner race is visible when installed.
Page 812 NOTE: Use an appropriate bearing installer or socket. Install the bearing in the lock cylinder housing. Item Part Number Description — Bearing slot 3511 Lock cylinder housing — Outer race — Bearing (in the "UP" position) — Ball — 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 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 Install the lock cylinder housing. Position the lock cylinder housing and the shaft assembly on the actuator housing. Make sure the upper and lower lock actuators are aligned. Install and compress the steering column position 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.
Page 816 21. NOTE: The narrow section of the keyhole in the lock gear should be in the one o'clock position. Install the lock gear. Use Ignition Lock Grease F0AZ-19584-A or equivalent meeting Ford specification ESA- M1C232-A to coat the lock gear.
Page 817 23. Install the upper bearing retainer firmly to engage the four retention tabs into the lock housing. 24. Install the turn indicator cancel cam. 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.
Page 819 SECTION 211-05: Steering Column Switches 2003 Mustang Workshop Manual SPECIFICATIONS Torque Specifications Description Nm lb-ft lb-in Ignition switch screws — Instrument panel reinforcement screws — Instrument panel steering column cover screws — Key release button bolt —...
Page 820: Steering Column Switches
SECTION 211-05: Steering Column Switches 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Steering Column Switches The steering column switches system consists of the following components: multifunction switch (13K359) key release button (manual transmission only) (3F527) ignition switch (11572) The integrated multifunction 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.
Page 821 SECTION 211-05: Steering Column Switches 2003 Mustang Workshop Manual DIAGNOSIS AND TESTING Steering Column Switches Refer to Wiring Diagrams Cell , Power Distribution for schematic and connector information. Refer to Wiring Diagrams Cell , Interval Wiper/Washer for schematic and connector information.
Page 822 check the connections to the vehicle. check the ignition switch position. 4. If the scan tool still does not communicate with the vehicle, refer to the scan tool manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the scan tool responds with: CKT914, CKT915 or CKT70 =ALL ECUS NO RESP/NOT EQUIP, refer to Section 418- NO RESP/NOT EQUIP for GEM, go to Pinpoint Test A.
Page 823 B1405 Driver Power Window Down REFER to Section 501-11 Circuit Short to Battery B1408 Driver Power Window Up REFER to Section 501-11 Circuit Short to Battery B1410 Driver Power Window Motor REFER to Section 501-11 Circuit Failure B1426 Lamp Safety Belt Circuit Short REFER to Section 413-01 to Battery...
Page 824 Circuit Failure B2488 RF Side Repeater Lamp Output REFER to Section 417-01 Circuit Failure C1189 Brake Fluid Level Sensor Input REFER to Section 413-01 Short Circuit to Ground C1223 Lamp Brake Warning Output REFER to Section 413-01 Circuit Failure C1225 Lamp Brake Warning Output REFER to Section 413-01...
Page 825 Disconnect: GEM C201b. Key in ON position. REPAIR the circuit(s) in Using the following table. measure the voltage between the question. TEST the system GEM, harness side and ground. for normal operation. Connector Pin Circuit C201a 400 (LB/BK) C201a 1006 (DG/WH) C201b 1001 (WH/YE) C201b...
Page 826 INSTALL a new ignition switch. REFER to Ignition Switch . TEST the system for normal operation. PINPOINT TEST C: NO POWER IN ACC Test Step Result / Action to Take C1 CHECK THE RADIO FOR NORMAL OPERATION Key in ON position. GO to Check the radio for normal operation.
Page 827 Measure the voltage between ignition switch C250 Pin B4, REPAIR the circuit in Circuit 1050 (LG/VT), harness side and ground; and between question.TEST system ignition switch C250 Pin B5, Circuit 1050 (LG/VT), harness side for normal operation. and ground. Are the voltages greater than 10 volts? E2 CHECK THE CONTINUITY OF THE IGNITION SWITCH Carry out the ignition switch continuity test.
Page 829: Multifunction Switch
SECTION 211-05: Steering Column Switches 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Multifunction Switch Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
Page 830 2. Disconnect the electrical connectors. 3. Remove the multifunction 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.
Page 831: Ignition Switch
SECTION 211-05: Steering Column Switches 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Ignition Switch Removal 1. Disconnect the battery ground cable. 2. Remove the lower instrument panel steering column cover. 1. Remove the screws. 2. Remove the lower instrument panel steering column cover.
Page 832 Remove the ignition switch. 1. Remove the screws. 2. Remove the ignition 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.
Page 834 SECTION 211-05: Steering Column Switches 2003 Mustang Workshop Manual REMOVAL AND INSTALLATION Key Release Button Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
Page 835 2. Remove the release button handle and the spring. 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 836 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual SPECIFICATIONS General Specifications Item Specification Lubricants and Sealants SAE 5W-20 Premium Synthetic Blend Motor Oil WSS-M2C153-H XO-5W20-QSP Diesel engine oil Refer to owner literature Gasoline Engine Oil Dye ESE-M99C103-B1 164-R3705 Threadlock®...
Page 837 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Engine NOTE: This section contains information, steps and procedures that may not be specific to your engine. This section covers general procedures and diagnosis and testing of the engine system, except for exhaust emission control devices, which are covered in the Powertrain Control/Emissions Diagnosis Manual.
Page 838 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual DIAGNOSIS AND TESTING Engine Special Tool(s) Commercially Available Leakdown Tester — Quick Disconnect Compression Tester 134-R0212 or equivalent Dial Indicator Gauge Adapter 303-007 (TOOL-6565-AB) or equivalent Dial Indicator Gauge with...
Page 839 Material Item Specification Gasoline Engine Oil ESE-M99C103-B1 164-R3705 or equivalent Refer to owner Engine Oil literature Inspection and Verification 1. Verify the customer concern by operating the engine to duplicate the condition. 2. Visually inspect for obvious signs of mechanical damage. Refer to the following chart. Visual Inspection Chart Mechanical Engine coolant leaks...
Page 840 REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual. Damaged charging REFER to Section 414-00 system/battery. Burnt valve. INSTALL a new valve. Worn piston. INSTALL a new piston. Worn piston rings. INSTALL new piston rings. Worn cylinder. REPAIR or INSTALL a new cylinder block.
Page 841 (PC/ED) manual. Damaged valve INSTALL a new valve tappet or tappet or lash lash adjuster. adjuster. Damaged valve INSTALL a new valve tappet tappet guide or guide or valve tappet. valve tappet. Burnt or sticking REPAIR or INSTALL a new valve.
Page 842 Seized or heat INSTALL a new crankshaft main damaged bearing. crankshaft main bearing. Excessive INSTALL a new thrust bearing or crankshaft end crankshaft (6303). play. Excessive INSTALL a new connecting rod connecting rod bearing or connecting rod bearing clearance. (6200). Heat damaged INSTALL a new connecting rod connecting rod...
Page 843 Slipping Refer to the appropriate section transmission. in Group for the procedure. Malfunctioning INSTALL a new valve tappet or valve tappet or lash lash adjuster. adjuster. Damaged valve INSTALL a new valve tappet tappet guide or guide or valve tappet. valve tappet.
Page 844 intake manifold gaskets cylinder head gaskets oil bypass filter oil filter adapter engine front cover oil filter adapter and filter body oil level indicator tube connection oil pressure sensor Leakage Points—Under Engine—With Vehicle on Hoist oil pan gaskets (6710) oil pan sealer oil pan rear seal (6723) engine front cover gasket crankshaft front seal (6700)
Page 845 required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Test—Test Results The indicated compression pressures are considered within specification if the lowest reading cylinder is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart. Compression Pressure Limit Chart Maximum Minimum...
Page 846 1. If compression improves considerably, piston rings are faulty. 2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition.
Page 847 6. Carry out an oil consumption test: a. Drain the engine oil, remove the oil bypass filter (6714) and refill with one liter (quart) less than the recommended amount. b. Run the engine for three minutes (10 minutes if cold), and allow the oil to drain back for at least five minutes with the vehicle on a level surface.
Page 848 Intake Manifold Vacuum Test Bring the engine to normal operating temperature. Connect the Vacuum/Pressure Tester to the intake manifold. Run the engine at the specified idle speed. The vacuum gauge should read between 51-74 kPa (15-22 in-Hg) depending upon the engine condition and the altitude at which the test is performed.
Page 849 4. WORN RINGS OR DILUTED OIL: When the engine is accelerated (dotted needle), the needle drops to 0 kPa (0 in-Hg). Upon deceleration, the needle runs slightly above 74 kPa (22 in-Hg). 5. STICKING VALVES: When the needle (dotted) remains steady at a normal vacuum but occasionally flicks (sharp, fast movement) down and back about 13 kPa (4 in-Hg), one or more valves may be sticking.
Page 850 Engines need oil to lubricate the following internal components: cylinder block cylinder walls pistons and piston, pin and rings (6102) intake and exhaust valve stems intake and exhaust valve guides all internal engine components When the pistons move downward, a thin film of oil is left on the cylinder walls. As the vehicle is operated, some oil is also drawn into the combustion chambers past the intake and exhaust valve stem seals and burned.
Page 851 excessive connecting rod bearing clearance Valve Train Analysis—Engine Off—Valve Cover Removed Check for damaged or severely worn parts and correct assembly. Make sure correct parts are used with the static engine analysis as follows. Valve Train Analysis—Engine Off, Rocker Arm Check for loose mounting bolts, studs and nuts.
Page 852 Valve Train Analysis—Engine Running Start the engine and, while idling, check for correct operation of all parts. Check the following: Valve Train Analysis—Engine Running, Valves and Cylinder Head Check for plugged oil drain back holes. Check for missing or damaged valve stem seals or guide mounted valve stem seals. Check for a plugged oil metering orifice in the cylinder head oil reservoir (4.6L engine only).
Page 853 9. Install the valve covers. Valve Train Analysis—Engine Running, Camshaft Lobe Lift—Push Rod Engine Check the lift of each lobe in consecutive order and make a note of the readings. 1. Remove the valve covers. 2. Remove the rocker arm seat bolts, rocker arm seat (6A528) and rocker arms. Typical Engine With Push Rods 3.
Page 854 incorrectly functioning valve tappet air in lubrication system excessive valve guide wear low oil pressure Excessive collapsed valve tappet gap can be caused by loose rocker arm seat bolts/nuts, incorrect initial adjustment or wear of valve tappet face, or worn roller valve tappets, push rod (6565), rocker arm (6564), rocker arm seat or valve tip.
Page 855 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Sprockets WARNING: To avoid the possibility of personal injury or damage to the vehicle, do not operate the engine with the hood open until the fan blade has been examined for possible cracks and separation.
Page 856 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Rocker Arms —Cleaning 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.
Page 857 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Rocker Arms —Inspection CAUTION: Do not attempt to true surfaces by grinding. Check the rocker arm pad, side rails and seat for excessive wear, cracks, nicks or burrs. Check the rocker arm seat bolt for stripped or broken threads.
Page 858 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES 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.
Page 859 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Push Rods —Inspection CAUTION: Do not attempt to straighten push rods. Check the ends of the push rods for nicks, grooves, roughness or excessive wear. Install new push rods as necessary.
Page 860 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Camshaft Journal —Diameter 1. Measure each camshaft journal diameter in two directions. If out of specification, install new components as necessary. Refer to the appropriate section in Group...
Page 861 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Camshaft Journal —Clearance, Push Rod Engines, Micrometer Method 1. NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance. Measure each camshaft bearing (6261) in two directions.
Page 863 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Camshaft Journal —Clearance, Plastigage Method Special Tool(s) Plastigage 303-D031 (D81L-6002-B) or equivalent NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance. 1. Remove the camshaft bearing cap and lay Plastigage across the surface. Refer to the appropriate section in Group for the procedure.
Page 865 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Camshaft End Play —Push Rod Engines Special Tool(s) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent 1. Remove the valve tappets. Refer to the appropriate section in Group for the procedure.
Page 867 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Camshaft End Play —OHC Engines Special Tool(s) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent 1. Remove the roller followers. Refer to the appropriate section in Group for the procedure.
Page 869 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Camshaft —Lobe Surface 1. Inspect camshaft lobes for pitting or damage in 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 for the procedure.
Page 870 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Camshaft Lobe Lift Special Tool(s) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent 1. Use a Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift.
Page 871 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Camshaft Runout Special Tool(s) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent 1. NOTE: Camshaft journals must be within specifications before checking runout. Use a Dial Indicator Gauge with Holding Fixture to measure the camshaft runout.
Page 873 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Crankshaft Main Bearing Journal —Diameter 1. Measure each of the crankshaft main bearing journal diameters in at least two directions. Refer to the appropriate section in Group for the procedure.
Page 874 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Crankshaft Main Bearing Journal —Taper 1. Measure each of the crankshaft main bearing journal diameters in at least two directions at each end of the main bearing journal.
Page 875 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Crankshaft Main Bearing Journal —Clearance Special Tool(s) Plastigage 303-D031 (D81L-6002-B) or equivalent NOTE: Crankshaft main bearing journals must be within specifications before checking journal clearance. 1. Remove the crankshaft main bearing caps and crankshaft main bearing.
Page 877 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Crankshaft End Play Special Tool(s) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent 1. Measure the crankshaft end play. Use a Dial Indicator Gauge with Holding Fixture to measure crankshaft end play.
Page 879 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Crankshaft Runout Special Tool(s) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent 1. NOTE: Crankshaft main bearing journals must be within specifications before checking runout.
Page 881 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Crankshaft —Connecting Rod Journal Taper, Out of Round 1. Measure the crankshaft connecting rod journal diameters in two directions perpendicular to one another at each end of the connecting rod journal. The difference in the measurements from one end to the other is the taper.
Page 882 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Cylinder Bore —Taper 1. Measure the cylinder bore at the top, middle, and bottom of piston ring travel in two directions as indicated. Verify the cylinder bore is within the wear limit. The difference indicates the cylinder bore taper.
Page 883 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Cylinder Bore —Out-of-Round 1. Measure the cylinder bore in two directions. 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.
Page 884 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Piston Inspection Special Tool(s) Scraper, Piston Ring Groove 303-D033 (D81L-6002-D) or equivalent CAUTION: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can occur.
Page 886 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Piston —Pin to Bore Diameter WARNING: Cover the end of the pin bore with a hand or shop rag when removing the retainer ring, since it has a tendency to spring out. Wear eye protection.
Page 888 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Piston —Diameter 1. Measure the piston diameter 90 degrees from the piston pin at the point indicated. Refer to the appropriate section in Group for the procedure.
Page 889 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Piston —to Cylinder Bore Clearance 1. Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore clearance.
Page 890 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Piston —Selection NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting a piston. 1. Select a piston size based on the cylinder bore.
Page 892 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Piston —Ring End Gap CAUTION: Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore. CAUTION: Piston rings should not be transferred from one piston to another.
Page 894 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Piston —Ring-to-Groove Clearance 1. Inspect the piston for ring land damage or accelerated wear. 2. Measure the piston ring-to-groove clearance. Refer to the appropriate section in Group for the procedure.
Page 896 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Piston —Pin Diameter 1. Measure the piston pin diameter in two directions at the points shown. Verify the diameter is within specification. Refer to the appropriate section in Group for the procedure.
Page 897 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Connecting Rod —Cleaning CAUTION: Do not use a caustic cleaning solution or damage to connecting rods can occur. 1. NOTE: The connecting rod large end is a matched set. The connecting rod cap must be installed on the original connecting rod in the original position.
Page 898 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Connecting Rod —Large End Bore 1. Tighten the bolts to specification, then measure the bore in two directions. The difference is the connecting rod bore out-of-round. Verify the out-of-round is within specification.
Page 899 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Connecting Rod —Bushing Diameter 1. Measure the inner diameter of the connecting rod bushing, if equipped. Verify the diameter is within specification. Refer to the appropriate section in Group for the procedure.
Page 900 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Connecting Rod —Bend 1. Measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification.
Page 901 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Connecting Rod —Twist 1. Measure the connecting rod twist on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the measurement is within specification.
Page 902 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Connecting Rod —Piston Pin Side Clearance 1. Measure the clearance between the connecting rod and the piston. Verify the measurement is within specification. Refer to the appropriate section in Group for the procedure.
Page 903 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Connecting Rod —Bearing Journal Clearance Special Tool(s) Plastigage 303-D031 (D81L-6002-B) or equivalent NOTE: The crankshaft connecting rod journals must be within specifications to check the connecting rod bearing journal clearance.
Page 905 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Connecting Rod —Side Clearance 1. Measure the clearance between the connecting rod and the crankshaft. Verify the measurement is within specification. Refer to the appropriate section in Group for the procedure.
Page 906 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Roller Follower —Inspection 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.
Page 908 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Valve Tappet —Inspection 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.
Page 910 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Valve —Stem Diameter 1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. Refer to the appropriate section in Group for the procedure.
Page 911 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Valve Stem to Valve Guide Clearance Special Tool(s) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Clearance Gauge, Valve Guide 303-004 (TOOL-6505-E) or equivalent NOTE: Valve stem diameter must be within specifications before checking valve stem to valve guide clearance.
Page 913 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Valve —Inspection 1. Inspect the following valve areas: 1. the end of the stem for grooves or scoring 2. the valve face and the edge for pits, grooves or scores 3.
Page 914 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Valve —Guide Inner Diameter 1. Measure the inner diameter of the valve guides in two directions where indicated. Refer to the appropriate section in Group for the procedure.
Page 915 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES 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.
Page 916 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Valve —Spring Installed Length 1. Measure the installed length of each valve spring. Refer to the appropriate section in Group for the procedure. If out of specification, install new components. Refer to the appropriate section in Group...
Page 917 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Valve —Spring Free Length 1. Measure the free length of each valve spring. Refer to the appropriate section in Group for the procedure. If out of specification, install new components as necessary. Refer to the appropriate section in Group for the procedure.
Page 918 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Valve —Spring Squareness 1. Measure the out-of-square on each valve spring. Turn the valve spring and observe the space between the top of the valve spring and the square.
Page 919 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Valve Spring Strength Special Tool(s) Pressure Gauge, Valve/Clutch Spring 303-006 (TOOL-6513-DD) or equivalent 1. Use a Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the specified valve spring length.
Page 921 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Valve —Seat Inspection Valve and Seat Refacing Measurements CAUTION: After grinding valves or valve seats, check valve clearance. 1. Check the valve head and seat. Check valve angles.
Page 922 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Valve —Seat Width 1. Measure the valve seat width. If necessary, grind the valve seat to specification. Measure the intake valve seat width. Measure the exhaust valve seat width.
Page 923 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Valve —Seat Runout 1. Use the Valve Seat Runout Gauge to check valve seat runout.
Page 924 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Cylinder Head —Distortion Special Tool(s) Straight Edge 303-D039 (D83L-4201-A) or equivalent 1. Use a straight edge and a feeler gauge to inspect the cylinder head for flatness. If the cylinder...
Page 925 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.
Page 926 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Cylinder Block Core Plug Replacement Special Tool(s) Slide Hammer 100-001 (T50T-100-A) Material Item Specification Threadlock® 262 WSK-M2G351-A6 E2FZ-19554-B or equivalent 1. Use a slide hammer or tools suitable to remove the cylinder block core plug.
Page 927 Expansion-Type CAUTION: 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 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Spark 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.
Page 929 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Spark Plug —Inspection 1. Inspect the spark plug for a bridged gap. Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling.
Page 930 4. Inspect for normal burning. Check for light tan or gray deposits on the firing tip. 5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing, wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug threads.
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 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Exhaust Manifold —Inspection Special Tool(s) Straight Edge 303-D039 (D83L-4201-A) or equivalent 1. Place a straight edge across the exhaust manifold flanges and check for warping with a feeler...
Page 933 SECTION 303-00: Engine System — General Information 2003 Mustang Workshop Manual GENERAL PROCEDURES Bearing —Inspection 1. Inspect bearings for the following defects. Possible causes are shown: 1. Cratering — fatigue failure. 2. Spot polishing — incorrect seating. 3. Imbedded dirt engine oil.
Page 935 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual SPECIFICATIONS General Specifications Item Specification Lubricants and Sealants SAE 5W-20 Premium Synthetic Blend Motor Oil WSS-M2C153-H XO-5W20-QSP Gasket and Trim Adhesive F3AZ-19B508-AA ESE-M2G52-A Pipe Sealant with Teflon® D8AZ-19554-A WSK-M2G350-A2 Silicone Gasket and Sealant F7AZ-19554-EA...
Page 936 Valve seat angle 44.75 degrees Valve spring free length — Valve spring squareness — Valve spring compression pressure — valve 1000 N (224 lbs) @ 29.2 mm (1.16 in) open (without damper) Valve spring compression pressure — valve 350 N (79 lbs) @ 40.7 mm (1.62 in) closed (without damper) Valve spring installed height 40.7 mm (1.62 in)
Page 937 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 0.025-0.035 mm (0.001-0.0014 in) —...
Page 938 — desired Connecting rod bearing-to-crankshaft clearance 0.022-0.069 mm (0.00086-0.0027 in) — allowable Connecting rod side clearance 0.11-0.49 mm (0.0047-0.0193 in) Balance Shaft Journal diameter 52.108-52.082 mm (2.0515-2.0505 in) Bore inside diameter 55.689-55.664 mm (2.192-2.191 in) Maximum runout 0.025 mm (0.001 in) End play 0.075-0.200 mm (0.003-0.008 in) 20-200 seconds to leakdown 3.18 mm (0.125 in) with 225 Newtons (50 pounds) load and tappet filled...
Page 939 A/C compressor bracket-to-cylinder head stud bolt — Oil level indicator tube-to-cylinder head bolt — Coolant recovery reservoir bracket-to-GOP bolts — Motor mount-to-subframe nuts 115 85 — Oil pan drain plug — Wire harness bracket to motor mount nut — Steering column pinch bolt —...
Page 940 — — — Cylinder head bolts — — — Crankshaft main bearing bolts and studs — — — Connecting rod cap bolts Refer to the procedure in this section Advance one-half turn after gasket contacts the sealing surface.
Page 941 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Engine The 3.8L engine has: a V-block with six cylinders and splayed crankpins. a distributorless ignition system. a multiport, sequential fuel injection (SFI) system. overhead valves. hydraulic valve tappets for automatic lash adjustment.
Page 942 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Engine Component View Cylinder Heads and Valve Train Components Item Part Number Description 9D477 EGR valve-to-exhaust manifold tube 6C342 Crankcase ventilation hose 6582 Valve cover — RH 12405...
Page 943 6A666 Positive crankcase ventilation valve 6565 Push rod 6564 Rocker arm 6A528 Rocker arm seat N807699 Bolt 6518 Valve spring retainer key 6514 Valve spring retainer 6513 Valve spring 6A517 Valve stem seal 611497 Bolt 6049 Cylinder head — LH 9448 Exhaust manifold gasket —...
Page 944 Item Part Number Description 6B288 Camshaft position sensor 8507 Water pump housing gasket 12A362 Camshaft synchronizer 6A618 Oil pump intermediate shaft 6020 Engine front cover gasket 6010 Cylinder block 6019 Engine front cover 6714 Oil bypass filter 6C315 Crankshaft position sensor 8501 Water pump 6312...
Page 945 Item Part Number Description 9F797 Engine wire harness 9E926 Throttle body 9F670 Idle air control gasket 9F715 Idle air control valve 9E498 Emissions vacuum harness 9424 Intake manifold (upper) 9H486 Intake manifold gasket (upper) 12029 Ignition coil...
Page 946 18801 Radio ignition interference capacitor 12281 Ignition wire set — LH 18696 Tube assembly 9424 Intake manifold (lower) 9439 Intake manifold gasket — RH 9439 Intake manifold gasket — LH 9A424 Intake manifold seal (rear) 6A008 Cylinder head-to-block dowel 6010 Cylinder block 6A373 Engine rear plate (automatic transmission)
Page 947 Item Part Number Description 6255 Distributor drive gear 6268 Timing chain 6A303 Engine balance shaft drive gear 6A304 Engine balance shaft driven gear 6C341 Balance shaft thrust plate 6A311 Engine dynamic balance shaft W705934 Woodruff key 6261 Camshaft bearing...
Page 948 6A333 Balance shaft front and rear bearing 6010 Cylinder block 6K564 Tappet guide plate and retainer — RH 6K564 Tappet guide plate and retainer — LH 6500 Valve tappet 376958 Balance shaft cover plug 6337 Crankshaft thrust main bearing 6701 Crankshaft rear oil seal 6A338 Crankshaft main bearing (lower)
Page 950 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual DIAGNOSIS AND TESTING Engine Refer to Section 303-00 for basic mechanical concerns or refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for driveability concerns.
Page 951 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Upper Intake Manifold Removal 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01 2. Remove the engine air cleaner outlet pipe. For additional information, refer to Section 303-12 3.
Page 952 7. Disconnect the differential pressure feedback 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 11. Disconnect the following: Ignition coil electrical connector. Radio 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.
Page 954 14. Remove and discard the upper intake manifold gasket. Installation 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 Stage 1: Tighten 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 5. Connect 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 9. Position the accelerator cable bracket 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 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Lower Intake Manifold Material Item Specification Silicone Gasket and Sealant WSE-M4G323- F7AZ-19554-EA or equivalent Metal Surface Cleaner F4AZ-19A536-RA or WSE-M5B392-A equivalent Removal 1. Remove the upper intake manifold. For additional information, refer to Upper Intake Manifold this section.
Page 960 8. Remove the heater bypass tube. For additional 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 13. Disconnect the electrical connector. 14. NOTE: Remove the fuel injection supply manifold and fuel 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.
Page 962 16. Remove and discard the intake manifold gaskets. Item Part Number Description 9439 Intake manifold gasket—RH 9441 Intake manifold gasket—LH 9A424 Intake manifold rear end seal (part of 9439) 9A425 Intake manifold front end seal (part of 9439) Installation 1. 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.
Page 963 2. Install the intake manifold gaskets. 3. 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.
Page 964 4. NOTE: Refer to the location note made during removal and make sure the bolts are installed in 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).
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 11. Install the heater bypass tube. For additional information, refer to Section 303-03A 12. 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.
Page 967 16. Install the upper intake manifold. For additional information, refer to Upper Intake Manifold this section. 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 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Valve Cover —LH Removal and Installation 1. Position the ignition wires (12281) aside. 2. Disconnect the positive crankcase ventilation (PCV) valve (6758). 3. Remove the ignition coil and position aside.
Page 969 5. To install, reverse the removal procedure.
Page 970 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Valve Cover RH Removal and Installation 1. Remove the throttle body. For additional information, 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.
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 973 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Crankshaft Pulley 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...
Page 974 5. Using the special tool, remove 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.
Page 975 4. Install the radiator coolant recovery reservoir. 5. Install the drive belt. For additional information, refer to Section 303-05...
Page 976 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Crankshaft Front Seal 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...
Page 977 1. NOTE: Lubricate the 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 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Engine Front Cover Material Item Specification Metal Surface Cleaner WSE-M5B392- F4AZ-19A536-RA or equivalent Silicone Gasket and Sealant WSE-M4G323- F7AZ-19554-EA or equivalent SAE 5W-20 Premium Synthetic WSS-M2C153- Blend Motor Oil...
Page 979 7. Disconnect the upper radiator hose 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 CAUTION: The cap screw is hidden; make sure to remove it or the engine front cover will be damaged. NOTE: Record the location, type and size of the fasteners. Remove the engine front cover. Slide the engine front cover off the two dowels. Remove and discard the engine front cover gasket.
Page 982 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.
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 9. Connect the crankshaft position sensor electrical connector. 10. Connect the lower 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.
Page 985 14. Connect the bypass hose 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 19. Drain the 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 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Rocker Arm Removal CAUTION: If removing more than one rocker arm (6564), mark the components removed for correct location. 1. Remove the valve covers. For additional information, refer to Valve Cover—LH...
Page 989 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Push Rod Removal CAUTION: Mark the components removed for correct location. 1. Remove the rocker arms (6564). For additional information, refer to Rocker Arm in this section. 2. Remove the push rods (6565).
Page 991 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Valve Springs Special Tool(s) Compressor, Valve Spring 303-163 (T81P-6513-A) Material Item Specification SAE 5W-20 Premium Synthetic WSS-M2C153- Blend Motor Oil XO-5W20-QSP or equivalent Removal 1. Remove the LH and the RH valve covers. For additional information, refer to Valve Cover—LH...
Page 992 5. Using the special tool, compress the valve springs. 6. Remove the valve 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.
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 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Valve Tappets Material Item Specification SAE 5W-20 Premium Synthetic WSS-M2C153- Blend Motor Oil XO-5W20-QSP or equivalent Removal CAUTION: If removing more than one valve tappet, mark the components removed for correct location.
Page 996 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Camshaft Material Item Specification SAE 5W-20 Premium Synthetic WSS-M2C153- Blend Motor Oil XO-5W20-QSP or equivalent Removal 1. Remove the valve tappets. For additional information, refer to Valve Tappets in this section.
Page 997 6. Remove the camshaft. 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 999 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Engine Dynamic Balance Shaft Removal 1. Remove the timing chain (6268). For additional information, refer to Timing Chain in this section. 2. Disconnect and position the wire harness aside.
Page 1000 1. Turn the camshaft so that the timing mark is at 12 o'clock and install the engine dynamic balance shaft assembly into the cylinder block (6010). Turn the engine balance shaft driven gear so that the timing mark lines up with the timing mark on the engine balance shaft drive gear (6A303).
Page 1001 5. Install the timing chain. For additional information, refer to Timing Chain in this section.
Page 1002: Timing Chain
SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Timing Chain Removal 1. Remove the timing cover. For additional information, refer to Engine Front Cover in this section. 2. Remove the camshaft position sensor drive gear. 1. Remove the bolt.
Page 1003 6. Remove the timing chain tensioner. 1. Remove the bolts. 2. Remove 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 3. If necessary, retract the tensioner pad retracting mechanism. 1. Compress the tensioner 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.
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 1007 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Exhaust Manifold —LH Removal 1. Raise and support the vehicle. For additional information, refer to Section 100-02 2. Remove the LH exhaust manifold flange nuts. 3. Remove the RH exhaust manifold flange nuts.
Page 1008 Installation 1. NOTE: Install a new gasket. NOTE: Tighten the nuts in the sequence shown. To install, reverse the removal procedure.
Page 1010 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Exhaust Manifold RH Removal and Installation 1. Disconnect the battery negative cable. For additional information, refer to Section 414-01 2. Remove the air cleaner outlet pipe. For additional information, refer to Section 303-12 3.
Page 1011 7. Remove the LH exhaust manifold flange nuts. 8. Remove the RH exhaust 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 1013 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Cylinder Head LH Special Tool(s) Remover, Power Steering Pump Pulley 211-016 (T69L-10300-B) Installer, Power Steering Pump Pulley 211-009 Material Item Specification SAE 5W-20 Premium Synthetic WSS-M2C153- Blend Motor Oil...
Page 1014 8. Remove 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 Remove the cylinder head. Discard the cylinder 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.
Page 1016 5. Tighten the bolts in three stages in the sequence shown. Stage 1: Tighten the bolts to 20 Nm (15 lb-ft). Stage 2: Tighten the bolts to 40 Nm (30 lb-ft). Stage 3: Tighten the bolts to 50 Nm (37 lb-ft). CAUTION: Do not loosen all of the bolts at one time.
Page 1017 9. Install the support bracket. 10. Using the special tool, install the power steering pump pulley. 11. Install the drive belt. For additional information, refer to Section 303-05 12. Install the push rods. For additional information, refer to Push Rod in this section.
Page 1019 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Cylinder Head RH Material Item Specification SAE 5W-20 Premium Synthetic WSS-M2C153- Blend Motor Oil XO-5W20-QSP or equivalent Removal 1. Disconnect the battery negative cable. For additional information, refer to Section 414-01 2.
Page 1020 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. Remove the cylinder head. Discard the cylinder 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.
Page 1021 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 the new long bolts. 2.
Page 1022 Loosen, then tighten the bolts in the sequence shown: Tighten 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.
Page 1023 9. Connect the A/C manifold and tube assembly. For additional information, refer to Section 412- 10. Install the accessory drive belt. For additional information, refer to Section 303-05 11. Install the push rods. For additional information, refer to Push Rod in this section.
Page 1024 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Oil Level Indicator and Tube Removal and Installation 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.
Page 1026 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Oil Pan 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 WSS-M2C153- Blend Motor Oil...
Page 1027 2. Remove the 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 9. Remove the LH engine mount 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 15. Remove the starter motor. 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 24. Remove the oil pan. Installation 1. 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.
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 11. Install the bracket. 12. Install 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 22. Install the air cleaner outlet pipe. For additional information, refer to Section 303-12 23. Connect the battery ground cable. For additional information, refer to Section 414-01 24. Fill the engine with clean engine oil. CAUTION: Correct coolant bleeding is critical for correct engine cooling. Fill and bleed the engine cooling system.
Page 1038 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Oil Pan Baffle Removal and Installation 1. Remove the oil pump screen cover and tube (6622). For additional information, refer to Pump Screen and Pickup Tube in this section.
Page 1039 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Flywheel 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.
Page 1041 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Oil Pump Screen and Pickup Tube Removal and Installation 1. Remove the oil pan (6675). For additional information, refer to Oil Pan in this section. 2. Remove the oil pump screen cover and tube (6622) and discard the gasket.
Page 1043 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Flexplate Removal and Installation 1. Remove the transmission. For additional information, refer to Section 307-01 2. Remove the six bolts retaining the flexplate to crankshaft, and remove the flexplate.
Page 1044 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Crankshaft Rear Seal Special Tool(s) Impact Slide Hammer 100-001 (T50T-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)
Page 1045 2. Using the special tools, remove the crankshaft rear seal. Installation 1. Clean and inspect the mating surface. 2. NOTE: Lubricate the crankshaft rear seal lips with clean engine oil prior to installation. Assemble the special tools and the crankshaft rear seal. 3.
Page 1046 5. Install the flywheel or the flexplate. For additional information, refer to Flexplate in this section.
Page 1047 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual IN-VEHICLE REPAIR Engine Support Insulators Special Tool(s) 3 Bar Engine Support Kit 303-F072 Engine Lift Bracket Set 303-D095 (D94L-6001-A) or equivalent Removal 1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414- 2.
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 10. Lower the vehicle. 11. Remove the special tools. 12. 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 1055 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual REMOVAL Engine Special Tool(s) Lifting Bracket Set, Engine 303-D095 (D94L-6001-A) or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Heavy Duty Floor Crane 014-00071 or equivalent Removal WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components.
Page 1056 6. Remove 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 Disconnect the power steering 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 14. Position the accelerator cable bracket (9723) aside. Remove the bolts. 15. Remove the air cleaner outlet tube (9B659) and the air cleaner assembly. 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.
Page 1059 20. Disconnect 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 23. Disconnect the evaporative emissions (EVAP) return tube (9G271). 24. Raise the vehicle on a hoist. 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.
Page 1061 29. Disconnect the engine 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 Vehicle 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 40. Lower the vehicle. 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 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual DISASSEMBLY Engine 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...
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 6. 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 10. Disconnect the idle air control (IAC) 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 14. Remove the positive crankcase 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 18. NOTE: Record the location of the long bolts and the short bolts. Remove the upper intake manifold and the upper intake manifold gasket. 19. Remove the fuel injection supply manifold and the fuel injectors. For additional information, refer Section 303-04A 20.
Page 1072 22. Disconnect 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 27. Remove the heater 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 39. Remove the bolts and the oil pan. 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.
Page 1077 42. NOTE: Record the location 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.
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 47. Remove the RH cylinder head and gasket. Discard the gasket. 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.
Page 1080 52. Remove the camshaft position sensor drive gear. 1. Remove the bolt. 2. Remove the camshaft 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.
Page 1081 56. Remove the engine dynamic balance shaft. Remove the bolts. Remove the balance shaft 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.
Page 1082 59. Remove the camshaft. 1. Remove the bolts. 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.
Page 1083 62. Remove the oil pan bridge and baffle assembly. CAUTION: The connecting rods and bearings are matched to the crankshaft journals. Make sure the components are marked and installed in the correct location. CAUTION: Each connecting rod and connecting rod cap are matched sets. They will fit together only one way.
Page 1084 Remove the four main bearing caps and lower crankshaft main bearings. 1. Remove the stud bolts. 2. Remove the main bearing cap and the lower crankshaft main bearing. 66. Repeat the main bearing cap and the lower bearing removal steps for the remaining main bearing caps and the crankshaft lower main bearings.
Page 1085 70. Using the camshaft bearing service set, remove the engine dynamic balance shaft bearings. 71. If equipped, remove the engine block heater. For additional information, refer to Section 303- 72. NOTE: For cleaning purposes, the plugs should be removed. If necessary, remove the following: 1.
Page 1087 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Cylinder Head Special Tool(s) Compressor, Valve Spring 303-163 (T81P-6513-A) Material Item Specification SAE 5W-20 Premium Synthetic WSS-M2C153- Blend Motor Oil XO-5W20-QSP or equivalent Disassembly and Assembly CAUTION: If the components are to be reinstalled, they must be installed in the same position.
Page 1088 4. Inspect the components. For additional information, refer to Section 303-00 CAUTION: Lubricate the parts with clean engine oil before installing. To assemble, reverse the disassembly procedure.
Page 1089 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Piston Special Tool(s) Piston Pin Tool or equivalent 303-D034 (D81L-6135-A) Material Item Specification SAE 5W-20 Premium Synthetic WSS-M2C153- Blend Motor Oil XO-5W20-QSP or equivalent Disassembly 1. Using the special tool, press the piston pin out from the connecting rod and piston assembly.
Page 1090 1. Lubricate the piston pin and piston pin 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 1092 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual ASSEMBLY Engine Special Tool(s) Slide Hammer 307-005 (T59L-100-B) Remover Adapter, Vibration Damper 303-176 (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)
Page 1093 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 WSE-M5B392- F4AZ-19A536-RA or equivalent Silicone Gasket and Sealant WSE-M4G323- F7AZ-19554-EA or equivalent SAE 5W-20 Premium Synthetic WSS-M2C153- Blend Motor Oil XO-5W20-QSP or equivalent...
Page 1094 4. Using the camshaft bearing service set, install the camshaft bearings. 5. Install the following: 1. the engine dynamic balance shaft bearing cover. 2. the camshaft bearing cover. CAUTION: Do not damage the camshaft lobes when installing the camshaft. Install the camshaft and the camshaft spacer.
Page 1095 7. Install the camshaft thrust plate. 1. Position the camshaft thrust plate. 2. Install the bolts. 8. Turn the camshaft so that the timing mark is at 12 o'clock and install the engine dynamic balance shaft assembly into the cylinder block. Turn the engine balance shaft driven gear so that the timing mark aligns up with the timing mark on the engine balance shaft drive gear.
Page 1096 CAUTION: The crankshaft journals must be protected from damage when installing the crankshaft. Position the crankshaft. CAUTION: The main bearings are precision selective fit. Inspect the bearing clearance. For additional information, refer to Section 303-00 12. NOTE: 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.
Page 1097 13. Install the main bearing caps. 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. CAUTION: Inspect the piston clearance. For additional information, refer to Section 303-00...
Page 1098 CAUTION: Do not damage the cylinder wall with the sharp edges of the connecting rod. Install the piston with the arrow on the piston face pointing toward the front of the engine. CAUTION: Inspect the connecting rod bearing clearance. For additional information, refer to Section 303-00 CAUTION: The connecting rod cap will fit only one way.
Page 1099 19. Install the oil pan bridge and baffle assembly. 20. Using a new gasket, 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.
Page 1100 23. Rotate the crankshaft so the number one piston is at top dead center (TDC) and the key is at the 12 o'clock position. 24. Turn the camshaft sprocket so that the keyway is on the bottom of the camshaft. 25.
Page 1101 28. Remove the retaining pin. CAUTION: The components removed should be marked for location. Make sure the used parts are installed in the correct 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.
Page 1102 31. 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). CAUTION: Do not loosen all of the bolts at one time. Each bolt must be loosened and tightened prior to working on the next bolt in the sequence.
Page 1103 Install the valve tappets. Install the tappet guide plates and retainers. Install the bolts. 34. NOTE: Lubricate the push rods with clean engine oil prior to installation. Install the 12 push rods. 35. Install the 12 rocker arms. For additional information, refer to Rocker Arm in this section.
Page 1104 Nm (21 lb-ft). 37. NOTE: Lubricate the parts with clean engine oil before 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 40. Install the crankshaft pulley bolt. 41. Install the camshaft synchronizer. For additional information, refer to Section 303-14 42. Install the water pump pulley and the retaining bolts. 43. 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.
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 50. Install the A/C compressor bracket and the bolts. 51. Install the accessory drive belt. 52. Refer to the illustration for intake manifold sealing components. Item Part Number Description 9439 Intake manifold gasket, RH 9441 Intake manifold gasket, LH 9A424 Intake manifold rear end seal (part of 9439)
Page 1109 9A425 Intake manifold front end seal (part of 9439) 53. 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.
Page 1110 56. Install the lower intake manifold 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.
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 63. Connect the engine oil pressure sender electrical connector. 64. Connect the camshaft 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.
Page 1113 68. NOTE: Refer to the location note made during removal and make sure the bolts are installed 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.
Page 1114 70. Connect the differential pressure feedback EGR system 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 75. Position and connect the RH spark plug wires. 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 78. Install the exhaust gas recirculation (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 87. NOTE: Lubricate the crankshaft rear seal lips with clean engine 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 1120 SECTION 303-01A: Engine — 3.8L 2003 Mustang Workshop Manual INSTALLATION Engine 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 WSS-M2C153- Blend Motor Oil XO-5W20-QSP or equivalent...
Page 1121 3. Remove the special tools. 4. Raise and support the vehicle. For additional 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.
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 17. Install the bracket. 18. Install the dual converter 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.
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 26. Connect the fuel supply tube spring lock coupling. For additional information, refer to Section 310-00 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.
Page 1127 32. Install 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 40. Connect the battery negative cable. For additional information, refer to Section 414-01 41. Fill the 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.
Page 1130 SECTION 303-01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual SPECIFICATIONS General Specifications Item Specification Lubricants and Sealants Silicone Gasket and Sealant F7AZ-19554-EA WSE-M4G323-A4 Premium Engine Coolant VC-4A, ESE-M97B44-A VC-5 in Oregon, CXC-10 in Canada Super Premium 5W-20 Motor Oil XO-5W20-QSP...
Page 1131 Valve spring installed height 42.3-42.9 mm (1.67-1.69 in) Valve spring installed pressure 283.0-321.0 N @ 42.56 mm (63.61 lb @ 1.68 in) Roller follower ratio — intake 2.02:1 Roller follower ratio — exhaust 2.03:1 Hydraulic Lash Adjuster Diameter 16.000-15.988 mm (0.6299-0.6294 in) Clearance-to-bore 0.018-0.069 mm (0.0007-0.0027 in) Service limit...
Page 1132 Connecting rod journal maximum taper 0.004 mm (0.0002 in) Connecting rod journal maximum out-of-round 0.05 mm (0.002 in) Crankshaft maximum end play 0.075-0.377 mm (0.003-0.015 in) Piston and Connecting Rod 90.185-90.205 mm (3.55-3.551 in) Piston diameter — code red 1 90.195-90.215 mm (3.55-3.551 in) Piston diameter —...
Page 1133 Specification in 90.200 mm diameter gauge. If applicable, measured vertically, +0.030-0.050 mm (0.001-0.002 inch) measured horizontally (oval pin bore). Pin bore and crank bearing bore must be parallel and in same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 101.5 mm on each side of rod centerline. Torque Specifications Description lb-ft lb-in...
Page 1134 Power steering reservoir bolts — Water outlet connector bolts — Camshaft cap cluster to cylinder head bolts — Torque converter nuts — Timing chain tensioner bolts — Transmission filler tube bolt — A/C compressor bolts — Ignition coil bolts — Generator brace bolts —...
Page 1136 SECTION 303-01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual DESCRIPTION AND OPERATION Engine...
Page 1138 Item Part Number Description 6150 Piston ring 6159 Piston ring 6159 Piston ring 6110 Piston 6135 Piston pin 6211 Connecting rod bearing 6214 Connecting rod bolt 6152 Piston ring...
Page 1139 6161 Piston ring 6200 Connecting rod assy. 6100 Piston and rod assy (8 req'd) N806164 Washer 6256 Camshaft sprocket 6265 Camshaft sprocket spacer 6766 Oil filler cap 6C324 Crankcase vent connector and hose 6582 Valve cover 6B280 Camshaft bearing cap 6250 Camshaft 9H308...

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