2003 FORD MUSTANG instrument cluster

DIAGNOSIS AND TESTING
Brake System
Refer to Wiring Diagrams Cell
60 , Instrument Cluster for schematic and connector information.
Refer to Wiring Diagrams Cell 97 , Daytime Running Lamps for schematic and connector information.
Inspection and Verification WARNING: Use of any other than the approved DOT 3 brake fluid will cause permanent
damage to brake components and will render the brakes inoperative.
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. Get medical attention if irritation persists. If taken internally,
drink water and induce vomiting. Get medical attention immediately.
CAUTION: Do not spill brake fluid onto painted surfaces. If spilled, wipe up immediately.
NOTE: Always check the fluid level in the brake master cylinder reservoir (2K478) before performing
the test procedures. If the fluid level is not at the correct level, add High Performance DOT 3 Brake
Fluid C6AZ- 19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA- M6C25-A.
NOTE: Prior to performing any diagnosis, make sure the brake warning indicator is functional. For
additional information, refer to Section 413 - 01 .
The first indication that something may be wrong in the brake system is a change in the feeling through
the brake pedal (2455). The brake warning indicator in the instrument cluster and the brake fluid level SECTION 206-
00: Brake System — General Information 2003 Mustang Workshop Manual Special Tool(s)
73 Digital Multimeter
105-
R0051 or Equivalent ABS Brake and Pressure Test
Kit
107-
02350 or Equivalent Tire and Wheel Runout Gauge
Set
134-
00199 or Equivalent Klj . 1 ba
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not machine a new brake disc.
7. For vehicles with a two- piece hub and brake disc assembly:
z Match-mark before disassembly.
z Remove the brake disc.
z Using a die grinder with a mild abrasive (Scotch Brite® type), remove any rust or
corrosion from the hub and brake disc mounting surfaces.
z Align the match- marks and reinstall the brake disc on the hub.
8. CAUTION: Do not use a bench lathe to machine brake discs.
NOTE: The depth of cut must be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter
cuts will cause heat and wear. Heavier cuts will cause poor brake disc surface finish.
Using on- vehicle brake lathe, machine the brake discs. Follow the manufacturer's instructions.
After machining, make sure the brake disc still meets the thickness specification.
9. Using a dial indicator, verify that the brake disc lateral runout is now within vehicle specification.
10. Remove any metal chips.
11. Remove the hub adapter.
12. Remove any remaining metal chips from the machining operation.
13. CAUTION: Do not carry out this step on rear drum- in-hat brake discs.
For vehicles with a two- piece hub and a non drum- in-hat brake disc assembly:
z Remove the brake disc from the hub.
z Remove any remaining metal chips from hub and brake disc mounting surfaces and from
the ABS sensor.
z Apply High Temperature Nickel Anti- Seize Lubricant F6AZ-9L494-AA to the mounting
surfaces.
z Using the match- marks, mount the brake disc on the hub.
14. Install the caliper and check brake operation.
Symptom Chart Symptom Chart
Condition
Possible Sources Action
z The Brakes Pull or
Drift z
Tire air pressure.
z Wheel alignment.
z Brake pads.
z Brake components.
z Suspension
component. z
Go To Pinpoint Test A .
z The Red Brake
Warning Indicator Is z
Instrument cluster.
z Circuit. z
Go To Pinpoint Test B . Klj . 4 ba
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Anti-Lock Brake Control Module Active Command Index
Symptom Chart 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-
BG, OFFOBG, ON---, ONO--, ON -B-, ON--G, ONO-
G, ON- BG, ONOBG ABSR_O Rear 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
Anti-Lock Brake Control Module Active
Command Index Active Command Display Action
ABS OUTPUT CONTROL ABS POWER OFF, ON
DSBL TOG OFF, ON
LF INLET OFF, ON
LF OUTLET OFF, ON
RF INLET OFF, ON
RF OUTLET OFF, ON
R INLET OFF, ON
R OUTLET OFF, ON
Symptom Chart
NOTE: Refer to the Wiring Diagrams for connector numbers stated in the Pinpoint
tests. Condition
Possible Sources Action
z No communication with the anti-
lock brake control module z
CJB Fuse 29
(15A).
z Circuitry.
z Anti- lock brake
control module. z
Go To Pinpoint Test A .
z Unable to enter self- test. zAnti- lock brake
control module. z
Go To Pinpoint Test B .
z The yellow ABS warning
indicator does not self- check z
Circuitry.
z Anti- lock brake
control module.
z Instrument cluster. z
Go To Pinpoint Test J .
z Spongy brake pedal with no zAir in the brake zGo To Pinpoint Klj . 4 ba
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PINPOINT TEST J: THE YELLOW ABS WARNING INDICATOR DOES
NOT SELF-
CHECK
PINPOINT TEST K: SPONGY BRAKE PEDAL WITH NO WARNING
INDICATOR PINPOINT TEST L: POOR VEHICLE TRACKING DURING ANTI - LOCK z
Is the resistance less than 5 ohms? No
REPAIR the circuit. CLEAR
the DTCs. REPEAT the self-
test.
Test Step Result / Action to Take
J1 CHECK THE ABS WARNING INDICATOR CIRCUITRY
z
Key in OFF position.
z Disconnect: Anti- Lock Brake Control Module C135.
z Key in ON position.
z Depress and release the shorting bar connector
internal to the anti- lock brake control module C135,
harness side, while checking the yellow ABS warning
indicator in the instrument cluster.
z Does the yellow ABS indicator illuminate with the
shorting bar released and turn OFF with the
shorting bar depressed? Yes
INSTALL a new anti-
lock brake
control module; REFER to
Module . TEST the system for
normal operation.
No
REFER to Section 413 - 01 .
Test Step Result / Action to Take
K1 CHECK THE VEHICLE COMPONENTS
z
Check the brake pedal and power
booster/brake master cylinder for correct
attachment.
z Are the components OK? Yes
GO to
K2 .
No
REPAIR as necessary. TEST the system for
normal operation. K2 BLEED THE BRAKE SYSTEM
z
Bleed the brake system; Refer to Section 206 - 00 .
z Check for spongy brake pedal.
z Is the brake pedal spongy? Yes
INSTALL a new HCU; REFER to
Hydraulic Control Unit . TEST the system for normal
operation.
No
The brake system is OK. TEST the system
for normal operation. Klj . 14 ba
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Pinpoint Tests
PINPOINT TEST A: NO COMMUNICATION WITH THE ANTI-
LOCK
BRAKE CONTROL MODULE test. Condition
Possible Sources Action
z No communication with the anti-
lock brake control module z
CJB Fuse 29
(15A).
z Circuitry.
z Anti- lock brake
control module. z
Go To Pinpoint Test A .
z Unable to enter self- test zAnti- lock brake
control module. z
Go To Pinpoint Test B .
z The yellow ABS warning indicator
does not self- check z
Circuitry.
z Anti- lock brake
control module.
z Instrument
cluster. z
Go To Pinpoint Test I .
z Spongy brake pedal with no
warning indicator z
Air in the brake
system.
z Base brake
system.
z Hydraulic control
unit (HCU). z
Go To Pinpoint Test J .
z REFER to
Section 206 -
00 .
z Poor vehicle tracking during anti-
lock function z
Air in the brake
system.
z Hydraulic control
unit (HCU).
z Base brake
system. z
Go To Pinpoint Test K .
z REFER to
Section 206 -
00 .
z The traction control is
inoperative— does not operate
correctly z
CJB 5 (15A).
z Circuitry.
z Traction control
switch.
z Instrument
cluster.
z Anti- lock brake
control module. z
Go To Pinpoint Test L .
z The traction control indicator is
inoperative— traction control
switch z
Circuitry.
z Traction control
switch.
z Instrument
cluster. z
Go To Pinpoint Test M .
Test Step Result / Action to
Take A1 CHECK CIRCUIT 601 (LB/PK) FOR AN OPEN
z
Key in OFF position.
z Disconnect: Anti- Lock Brake Control Module C141.
z Key in ON position.
z Measure the voltage between anti- lock brake control module C141
Pin 8, Circuit 601 (LB/PK), harness side and ground. Yes
GO to
A2 .
No
REPAIR the circuit. Klj . 6 ba
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PINPOINT TEST J: SPONGY BRAKE PEDAL WITH NO WARNING
INDICATOR
PINPOINT TEST K: POOR VEHICLE TRACKING DURING ANTI-
LOCK
FUNCTION Test Step Result / Action to Take
I1 CHECK THE ABS WARNING INDICATOR CIRCUITRY
z
Key in OFF position.
z Disconnect: Anti- Lock Brake Control Module C141.
z Key in ON position.
z Depress and release the shorting bar connector
internal to the anti- lock brake control module C141,
harness side, while checking the yellow ABS warning
indicator in the instrument cluster.
z Does the yellow ABS indicator illuminate with the
shorting bar released and OFF with the shorting
bar depressed? Yes
INSTALL a new anti-
lock brake
control module; REFER to
Module . TEST the system for
normal operation.
No
REFER to Section 413 - 01 .
Test Step Result / Action to Take
J1 CHECK THE VEHICLE COMPONENTS
z
Check the brake pedal and power
booster/brake master cylinder for correct
attachment.
z Are the components OK? Yes
GO to
J2 .
No
REPAIR as necessary. TEST the system for
normal operation. J2 BLEED THE BRAKE SYSTEM
z
Bleed the brake system; REFER to Section 206 - 00 .
z Check for spongy brake pedal.
z Is the brake pedal spongy? Yes
INSTALL a new HCU; REFER to
Hydraulic Control Unit . TEST the system for normal
operation.
No
The brake system is OK. TEST the system
for normal operation. Test Step Result / Action to Take
K1 BLEED THE BRAKE SYSTEM
z
Bleed the brake system; REFER to Section 206 - 00 .
z Check for vehicle tracking poorly.
z Does the vehicle track poorly? Yes
GO to
K2 .
No
The brake system is OK. TEST the
system for normal operation. K2 CHECK THE LF ABS VALVE OPERATION
z
Lift the vehicle and rotate all the wheels to
make sure they rotate freely (the vehicle must
be in neutral).
z NOTE: Trigger must be depressed twice.
Each depress runs the pump motor for two
seconds. Yes
INSTALL a new HCU; REFER to
Hydraulic Control Unit
. TEST the system
for normal operation.
No Klj . 15 ba
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PINPOINT TEST L: THE TRACTION CONTROL IS INOPERATIVE—
DOES NOT OPERATE CORRECTLY K8 CHECK THE RR ABS VALVE OPERATION
z
NOTE: Trigger must be depressed twice.
Each depress runs the pump motor for two
seconds.
z Trigger the anti- lock brake control module
active command PMP MOTOR ON for four
seconds.
z Apply moderate brake pedal effort.
z Have an assistant attempt to rotate the RR
wheel while the pump motor is running.
z Does the RR wheel rotate? Yes
INSTALL a new HCU; REFER to
Hydraulic Control Unit
. TEST the system
for normal operation.
No
GO to K9 .
K9 CHECK THE RR ABS VALVE RELEASE
z
Apply moderate brake pedal effort.
z Trigger the anti- lock brake control module
active command RF INLET and RF OUTLET.
z NOTE: The scan tool will energize the valves
for only two seconds per trigger press.
z Have an assistant rotate the RR wheel
immediately after depressing trigger.
z Does the RR wheel rotate? Yes
The ABS system is operating correctly.
No
GO to
K10 .
K10 CHECK FOR DTCS
z
Carry out the anti- lock brake control module
self- test.
z Are any DTCs retrieved? Yes
GO to the Anti-
Lock Brake Control Module
Diagnostic Trouble Code (DTC) Index.
No
INSTALL a new HCU; REFER to
Hydraulic Control Unit . TEST the system
for normal operation. Test Step Result / Action to Take
L1 CHECK THE TRACTION CONTROL SWITCH CIRCUITRY
z
Key in OFF position.
z Disconnect: Instrument Cluster C251.
z Key in ON position.
z Measure the voltage between instrument cluster C251 Pin 9,
Circuit 959 (GY), harness side and ground, while depressing
and releasing the traction control switch.
z Is the voltage greater than 10 volts with the traction control
switch depressed and zero volts with the traction control
switch released? Yes
INSTALL a new
instrument cluster,
REFER to
Section 413 -
01 . TEST the system
for normal operation.
No
GO to L2 . Klj . 17 ba
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PINPOINT TEST M: THE TRACTION CONTROL INDICATOR IS
INOPERATIVE—
TRACTION CONTROL SWITCH L2 CHECK CIRCUIT 959 (GY) FOR AN OPEN
z
Key in OFF position.
z Disconnect: Traction Control Switch C239.
z Measure the resistance between instrument cluster C251 Pin 9,
Circuit 959 (GY), harness side and traction control switch C239
Pin 4, Circuit 959 (GY), harness side.
z Is the resistance less than 5 ohms? Yes
GO to
L3 .
No
REPAIR the circuit.
TEST the system for
normal operation. L3 CHECK CIRCUIT 489 (PK/BK) FOR AN OPEN
z
Key in ON position.
z Measure the voltage between traction control switch C239 Pin
3, Circuit 489 (PK/BK), harness side and ground.
z Is the voltage greater than 10 volts? Yes
INSTALL a new traction
control switch. TEST the
system for normal
operation.
No
REPAIR the circuit.
TEST the system for
normal operation.
Test Step Result / Action to
Take M1 CHECK CIRCUIT 960 (BK/LB)
z
Key in OFF position.
z Disconnect: Instrument Cluster C251.
z Disconnect: Traction Control Switch C239.
z Measure the resistance between instrument cluster C251 Pin 8,
Circuit 960 (BK/LB), harness side and traction control switch C239
Pin 5, Circuit 960 (BK/LB), harness side; and between instrument
cluster C251 Pin 8, Circuit 960 (BK/LB), harness side and ground. Yes
GO to
M2 .
No Klj . 18 ba
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