2003 FORD MUSTANG engine

DIAGNOSIS AND TESTING
Transmission Cooling
Inspection and Verification
WARNING: Never remove the radiator cap under any conditions while the engine is
operating. Failure to follow these instructions could result in personal injury and/or damage to
the cooling system or engine. To avoid having scalding hot coolant or steam blow out of the
radiator, use extreme care when removing the radiator cap from a hot radiator. Wait until the
engine has cooled, then wrap a thick cloth around the radiator cap and turn it slowly to the first
stop. Step back while the pressure is released from the cooling system. When you are certain
all the pressure has been released, press down on the radiator cap (with a cloth), turn and
remove.
The transmission fluid cooler is integral to the radiator (8005). Whenever leaks or damage to the
radiator are found, install an entire new radiator. For additional information, refer to Section 303 - 03A or
Section 303 - 03B .
Symptom Chart SECTION 307-
02: Transaxle/Transmission Cooling 2003 Mustang Workshop Manual SYMPTOM CHART
Condition
Possible Sources Action
z Transmission
Overheating z
Damaged radiator. zREPAIR or install a new
radiator. For additional
information, REFER to
Section 303 - 03A or
Section 303 - 03B .
z System leaks. zINSPECT for leaks. REPAIR
as necessary.
z Incorrect fluid level. zADJUST to proper level.
z Fluid condition. zINSPECT according to
instructions under Fluid
Condition Check. REFER to
Section 307 - 01 .
z Damaged, blocked,
reversed, leaking or
restricted cooler lines
or cooler tubes. z
INSPECT cooler lines and
tubes. REPAIR or flush as
necessary.
z Engine concerns
causing transmission
to overheat. z
INSPECT engine cooling
system. For additional
information, REFER to
Section 303 - 03A or
Section 303 - 03B .
z Excessive towing
loads. z
CHECK gross vehicle weight.
z Incorrect idle or
performance. z
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual. Klj . 1 ba
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REMOVAL AND INSTALLATION
Transmission Fluid Cooler Tubes
Removal
1. Disconnect the battery cables.
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the nuts.
4. Remove the fluid cooler tube bracket at the engine.
5. NOTE: Use a backup wrench to hold the case fitting secure.
Remove the fluid cooler tubes at the transmission. Installation SECTION 307-
02: Transaxle/Transmission Cooling 2003 Mustang Workshop Manual Klj . 1 ba
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1.
NOTE: Use a backup wrench to hold the case fitting secure.
Install the fluid cooler tubes at the transmission.
2. Install the fluid cooler tube bracket at the engine.
3. Install the nuts.
4. Lower the vehicle.
5. Connect the battery cables.
6. Fill the transmission with fluid and verify proper operation. zUse Motorcraft MERCON® V Automatic Transmission Fluid XT -5-QM or equivalent
meeting MERCON® V specification. Klj . 2 ba
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DESCRIPTION AND OPERATION
Manual Transmission and Clutch
The primary function of the clutch is to couple and uncouple engine power to the transmission upon
driver command. For additional information, refer to
Section 308 - 01 .
Clutch Disc and Clutch Pressure Plate — 3.8L
SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Item Part Number Description
1 6397 Flywheel housing to block dowel (2 req'd)
2 — Rear face of block and flywheel (part of 6010)
3 6397 Flywheel to clutch pressure plate dowel (3 req'd)
4 7600 Pilot bearing
5 7550 Clutch disc
6 7563 Clutch pressure plate Klj . 1 ba
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Clutch Disc and Clutch Pressure Plate —
4.6L (4V)
z The clutch is a single plate, dry friction clutch disc. The clutch disc has a splined hub with
integral torsional springs. The clutch disc hub attaches to the input shaft.
z Engine output is coupled to the transmission input shaft by friction existing between the clutch
disc facings and the flywheel/clutch pressure plate assembly. The extent of this friction is directly related to the composition of the facing material and the magnitude of the clamping 12 7548 Clutch release hub and bearing
13 N808969-
S100 Bolt
14 N808969-
S100 Bolt (6 req'd)
15 — Rear face of block and flywheel (part of 6010)
16 — Bolt (3 req'd)
17 6397 Flywheel housing to block dowel (2 req'd)
Item Part Number Description
1 6375 Flywheel
2 7600 Pilot bearing
3 7550 Clutch disc
4 7563 Clutch pressure plate
5 7548 Clutch release hub and bearing
6 7515 Clutch release lever
7 7B602 Clutch release lever stud
8 6392 Flywheel housing
9 N808969-S100 Clutch pressure plate bolt (6 req'd) Klj . 3 ba
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forces exerted by the clutch pressure plate and the flywheel on the facings. These factors limit
the amount of torque that can be transmitted without slippage.
z The clamping force is obtained from a diaphragm spring contained within the clutch pressure
plate assembly. This force is developed during the attachment of the clutch pressure plate
assembly to the flywheel.
z The clutch system is disengaged when the clutch pedal is pressed and is accomplished when
the release fingers are fully displaced toward the flywheel. This displacement removes the
spring load from the clutch pressure plate and eliminates the coupling friction between the
engine and the transmission.
z When the clutch pedal is depressed a cable connected to the clutch release lever, hub and
bearing actuates the clutch pressure plate diaphragm spring, releasing pressure on the clutch
disc. This eliminates the engagement between the transmission and the engine. Klj . 4 ba
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DIAGNOSIS AND TESTING
Manual Transmission and Clutch
Inspection and Verification
It is important to get an accurate description of the concern before any diagnosis can be carried out.
Ask questions as to whether it occurs when hot or cold, during shifting, driving at a particular speed or
in a particular gear. If possible, have the customer demonstrate the concern.
zWith the vehicle at a complete stop, shift through all the gears and evaluate the noise at
different engine rpm. Check for any noises in NEUTRAL at different engine rpm.
Symptom Chart SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Symptom Chart
Condition
Possible Sources Action
z Clutch slippage zClutch pedal
sticking.
z Pressure plate
diaphragm
spring damaged
or weakened.
z Clutch pressure
plate damaged.
z Clutch disc
facing damaged
or worn
excessively.
z Clutch disc
facing surface
hardened or oil-
coated.
z Clutch release
hub and bearing
binding.
z Flywheel glazed
or damaged.
z loose pressure
plate to flywheel
bolts z
Go To Pinpoint Test A .
z Clutch chatter or shudder zLoose or worn
engine mount.
z Loose pressure
plate to flywheel
bolts
z Oil on clutch
disc facing.
z Clutch pressure
plate damaged z
Go To Pinpoint Test B . Klj . 1 ba
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or excessive
runout.
z Clutch disc
facing surface
hardened or
damaged.
z Flywheel
surface glazed
or damaged.
z Transmission
input shaft
eccentric or not
perpendicular.
z Clutch drag zClutch drag.
z Cable release
linkage outside
the flywheel
housing worn,
cracked, bent.
z Excessive
runout or
damaged clutch
disc.
z Clutch disc
splines rusted or
worn.
z Loose pressure
plate to flywheel
bolts. z
Go To Pinpoint Test C .
z Clutch pedal pulsation zClutch disc
damaged or
worn.
z Excessive
flywheel runout.
z Loose pressure
plate to flywheel
bolts.
z Improperly
assembled
release lever to
pivot stud. z
Go To Pinpoint Test D .
z Clutch related vibrations zEngine
component
grounding
against frame.
z Loose flywheel
bolts.
z Excessive
flywheel runout.
z Imbalanced
clutch pressure
plate.
z Accessory drive
belt loose or
damaged. z
Go To Pinpoint Test E .
z Hard shifting zManual
transmission
concern.
z Loose pressure
plate to flywheel
bolts. z
Go To Pinpoint Test F . Klj . 2 ba
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