2003 FORD MUSTANG clutch

DIAGNOSIS AND TESTING
Transmission Connector Layouts
Transmission Vehicle Harness Connector
Transmission Internal Harness Connector SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Pin Number Circuit Circuit Function
1 — NOT USED
2 — Signal Return
3 — Torque Converter Clutch (TCC) Solenoid
4 — Vehicle Power
5 — Transmission Fluid Temperature (TFT) Input
6 — Electronic Pressure Control (EPC) Solenoid
7 — SSA
8 — SSB
9 — NOT USED
10 — NOT USED Klj . 1 ba
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Digital Transmission Range (TR) Sensor Connector Pin Number Circuit Circuit Function
1 — NOT USED
2 — Signal Return Transmission Fluid Temperature (TFT)
3 — Torque Converter Clutch (TCC)
4 — Vehicle Power To Solenoid
5 — Transmission Fluid Temperature (TFT)
6 — Electronic Pressure Control
7 — SSA
8 — SSB
9 — NOT USED
10 — NOT USED
Pin Number Circuit Circuit Function Klj . 2 ba
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a
No engine braking.
Shift Solenoid Failure Mode Chart "Always On"
Failed on due to powertrain control module and or vehicle wiring concerns, shift solenoid electrically or
hydraulically stuck on.
a No engine braking.
a No engine braking.
PINPOINT TEST A: SHIFT AND TORQUE CONVERTER CLUTCH
SOLENOIDS SSB ALWAYS OFF: Gear Lever Position
(D) 2 1
PCM Gear
Commanded Actual Gear
Obtained
1 1 1 1
2 2 2 2
3 2 2 2
4 1 1 1
SSA ALWAYS ON: Gear Lever Position
(D) 2 1
PCM Gear
Commanded Actual Gear
Obtained
1 1 1 1
2 1 1 1
3 4
2
a 2
a 4 4
2
a 2
a SSB ALWAYS ON: Gear Lever Position
(D) 2 1
PCM Gear
Commanded Actual Gear
Obtained
1 4
2
a 2
a 2 3
2
a 2
a 3 3
2
a 2
a 4 4
2
a 2
a Test Step Result / Action to Take
NOTE:
Read and record all DTCs. All digital TR Sensor and VSS DTCs must be repaired before
entering Output State Control (OSC). NOTE:
Refer to the Transmission Internal Harness illustration preceding these pinpoint tests. Klj . 3 ba
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NOTE:
Refer to the Transmission Vehicle Harness Connector illustration preceding these
pinpoint tests. A1 ELECTRONIC DIAGNOSTICS
z
Select PARK.
z Key in OFF position.
z Check to make sure the transmission harness connector
is fully seated, pins are fully engaged in connector and
in good condition before proceeding.
z Connect the diagnostic tool.
z Key in ON position.
z Enter the following diagnostic mode on the diagnostic
tool: Diagnostic Data Link.
z Enter the following diagnostic mode on the diagnostic
tool: PCM.
z Enter the following diagnostic mode on the diagnostic
tool: Active Command Modes.
z Enter the following diagnostic mode on the diagnostic
tool: Output State Control (OSC).
z Enter the following diagnostic mode on the diagnostic
tool: Trans- Bench Mode.
z Does vehicle enter Trans- Bench Mode? Yes
GO to
A2 .
No
REPEAT procedure to enter
Trans-Bench Mode. If vehicle
did not enter Trans- Bench
Mode, REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual for diagnosis
of PCM. A2 WIGGLE TEST
z
Select PIDs to be monitored.
z Select "ON" to turn suspect solenoid on.
z Press "SEND".
z Wiggle all wiring and connectors to the transmission.
Monitor the Solenoid State for changes.
z Select "OFF" to turn solenoid off.
z Press "SEND".
z Does the suspect solenoid(s) fault state change? PID Command PID Actual
SSA SS1F
SSB SS2F
TCC TCCF Yes
REPAIR open or short in the
vehicle harness or connector.
No
GO to
A3 .
A3 SOLENOID FUNCTIONAL CHECK
z
Monitor each solenoid state.
z Turn each solenoid ON and OFF.
z Does the solenoid turn ON and OFF when
commanded and can solenoid activation be heard? Yes
GO to
A4 .
No
GO to A5 .
A4 OSC TRANS-
DRIVE MODE (GR_CM OR TCC) z
Carry out OSC Trans- Drive Mode.
z Select GR_CM for Shift Solenoids or follow procedures
for GR_CM as listed.
z Select TCC for Torque Converter Clutch Solenoid.
Follow procedures of TCC in Drive Mode as listed.
z Does the transmission upshift and downshift or
torque converter engage/disengage when
commanded? Yes
CLEAR all DTCs. ROAD TEST
to verify if concern is still
present. If concern is still
present, REFER to
Diagnosis By Symptom in this section to
diagnose shift or torque
converter concern.
No
GO to A5 .
A5 CHECK FOR BATTERY VOLTAGE
z
Remove transmission fluid pan. Yes Klj . 4 ba
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DIAGNOSIS AND TESTING
Special Testing Procedures
The special tests are designed to aid the technician in diagnosing the hydraulic and mechanical portion
of the transmission.
Engine Idle Speed Check
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for diagnosis and testing of the
engine idle speed.
Line Pressure Test
CAUTION: Carry out the line pressure test prior to carrying out the stall speed test. If the
line pressure is low at stall, do not carry out stall speed test or further transmission damage
will occur. Do not maintain WOT in any transmission range for more than five seconds.
This test verifies that the line pressure is within specification.
1. Connect pressure gauge to line pressure tap.
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Item Part Number Description
1 — Direct clutch pressure tap
2 — Forward clutch pressure tap
3 — Electronic pressure control (EPC) pressure tap
4 — Intermediate clutch pressure tap
5 — Line pressure tap Klj . 1 ba
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2. Start engine and check line pressures. Refer to the Line Pressure Chart to determine if line
pressure is within specification.
a EPC readings will vary due to EEC strategy. These values are approximate pressures. Actual clutch
apply pressures should be within 69- 103 kPa (10-15 psi) of line pressure. For additional information on
testing, refer to the Clutch Pressure Test in this section. Line Pressure Chart Application Range Idle WOT Stall
EPC Line Pressure EPC Line Pressure
4.6L P, N, OD,
2, 1 207-
276 kPa
(30- 40 psi) 552-
689 kPa (80-
100 psi) 689-
758 kPa
(100- 110 psi) 1310-1448 kPa
(190- 210 psi) 4.6L R 13-
82 kPa (2-
12 psi) 441-
683 kPa (64-
99 psi) 572-
655 kPa
(83- 95 psi) 1427-
1855 kPa
(207- 269 psi) 3.8L P, N, OD,
2, 1 138-
207 kPa
(20- 30 psi) 448-
586 kPa (65-
85 psi) 689-
758 kPa
(100- 110 psi) 1310-1448 kPa
(190- 210 psi) 3.8L R 103-
172 kPa
(15- 25 psi) 448-
620 kPa (65-
90 psi) 572-
662 kPa
(83- 96 psi) 1427-
1862 kPa
(207- 270 psi)
Clutch Pressure Chart 3.8L Transmission Pressures with TP at 1.5 Volts and Vehicle Speed Above 8 Km/h (5 MPH)
Gear EPC Tap
a Line Pressure
Tap Forward Clutch
Tap Intermediate
Clutch Tap Direct Clutch
Tap M1 172-
241 kPa
(25-35 psi) 517-
655 kPa (75-
95 psi) 448-
586 kPa (65-
85 psi) 0-
34 kPa (0-5 psi) 0-
34 kPa (0-5
psi) M2 103-
241 kPa
(15-25 psi) 413-
551 kPa (60-
80 psi) 344-
482 kPa (50-
70 psi) 393-
517 kPa (55- 75
psi) 0-
34 kPa (0-5
psi) 1 172-
241 kPa
(25-35 psi) 517-
655 kPa (75-
95 psi) 448-
586 kPa (65-
85 psi) 0-
34 kPa (0-5 psi) 0-
34 kPa (0-5
psi) 2 103-
241 kPa
(15-25 psi) 413-
551 kPa (60-
80 psi) 358-
468 kPa (52-
68 psi) 379-
517 kPa (55- 75
psi) 0-
34 kPa (0-5
psi) 3 137-
206 kPa
(20-30 psi) 413-
517 kPa (60-
75 psi) 413-
517 kPa (60-
75 psi) 413-
551 kPa (60- 80
psi) 379-
517 kPa
(55- 75 psi) 4 172-
241 kPa
(25-35 psi) 517-
655 kPa (75-
95 psi) 0-
34 kPa (0- 5
psi) 482-
620 kPa (70- 90
psi) 448-
586 kPa
(65- 85 psi)
Clutch Pressure Chart 4.6L Transmission Pressures with TP at 1.5 Volts and Vehicle Speed Above 8 Km/h (5 MPH)
Gear EPC Tap
a Line Pressure
Tap Forward Clutch
Tap Intermediate
Clutch Tap Direct Clutch
Tap M1 172-
241 kPa
(25-35 psi) 517-
655 kPa (75-
95 psi) 448-
586 kPa (65-
85 psi) 0-
34 kPa (0-5 psi) 0-
34 kPa (0- 5
psi) M2 103-
241 kPa
(15-25 psi) 413-
551 kPa (60-
80 psi) 344-
482 kPa (50-
70 psi) 393-
517 kPa (55- 75
psi) 0-
34 kPa (0- 5
psi) 1 172-
241 kPa 517-
655 kPa (75- 448-
586 kPa (65- 0-
34 kPa (0-5 psi) 0-
34 kPa (0- 5 Klj . 2 ba
72003 Mustang Workshop Manual
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a
EPC readings will vary due to EEC strategy. These values are approximate pressures. Actual clutch
apply pressures should be within 69- 103 kPa (10-15 psi) of line pressure. For additional information on
testing, refer to the Clutch Pressure Test in this section.
3. Place the ignition switch in the OFF position. If line pressure is not within specification, check EPC pressure.
4. Connect pressure gauge to EPC pressure tap.
5. Start engine and check EPC pressure. Use the line pressure chart for specifications.
6. If EPC pressure is not within specification, Go To Pinpoint Test E to diagnose EPC operation. If
EPC operation is OK, see the line pressure diagnosis chart for line pressure concern causes. (25-
35 psi) 95 psi) 85 psi) psi)
2 103-
241 kPa
(15-25 psi) 413-
544 kPa (60-
79 psi) 344-
482 kPa (50-
70 psi) 379-
517 kPa (55- 75
psi) 0-
34 kPa (0- 5
psi) 3 172-
241 kPa
(25-35 psi) 517-
655 kPa (75-
95 psi) 372-
579 kPa (54-
84 psi) 482-
613 kPa (70- 89
psi) 379-
586 kPa
(55-85 psi) 4 241-
310 kPa
(35-45 psi) 620-
758 kPa (90-
110 psi) 0-
34 kPa (0-5
psi) 586-
730 kPa (85-
105 psi) 551-689 kPa
(80-100 psi)
Line Pressure Diagnosis Chart Test Results Possible Source
High At Idle —
In All
Positions ·
Wiring Harnesses ·
Run Quick Test. Refer to the Powertrain Control/Emissions Diagnosis
(PC/ED) manual. ·
EPC Solenoid ·
Main Regulator Valve Low At Idle —
In All
Positions ·
Low Fluid Level ·
Control Bodies ·
Leakage in Pump ·
Damaged Gaskets on Separator Valve ·
Damaged Separator Plate ·
Restricted Inlet Filter ·
Case Bolts ·
Loose Main Control Valve Body ·
EPC Solenoid O- Ring ·
EPC Solenoid Bracket ·
Case ·
Sticking Main Regulator Valve ·
Damaged Inlet Tube Seal on Inlet Filter Low In Park Only ·
Valve Body ·
Low/Reverse Servo Low In Reverse Only ·
Separator Plate ·
Low/Reverse Servo or Valve Bodies Klj . 3 ba
72003 Mustang Workshop Manual
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Stall Speed Test
WARNING: Apply the parking brake firmly while carrying out each stall test.
CAUTION: Carry out line pressure test prior to carrying out stall test. If the line pressure is
low at stall, do not carry out stall test or further transmission damage will occur.
The stall speed test checks:
zthe torque converter clutch operation and installation.
z the holding ability of the forward clutch.
z the reverse clutch (the low- reverse bands).
z the planetary one- way clutch.
z the engine driveability.
Conduct this test with the engine coolant and transmission fluid at correct levels and at normal
operating temperature.
Apply the parking brake firmly for each stall speed test. 1. Find the specified stall rpm for the vehicle; see the stall speed diagnosis chart. Use a grease pencil to mark the rpm on the dial of a tachometer.
2. Connect a tachometer to the engine.
3. NOTE: If the rpm recorded by the tachometer exceeds the maximum limits, release the
accelerator pedal immediately because clutch or band slippage is indicated.
In each of the following ranges (D), 2, 1, R, press the accelerator pedal to the floor and hold it ·
Reverse Clutch Low In Neutral Only ·
Valve Body Low In Overdrive Only ·
Forward Clutch ·
Valve Body Low In 1st Position Only ·
Forward Clutch ·
Valve Body ·
Low/Reverse Servo Low In 2nd Only ·
Intermediate Clutch ·
Valve Bodies ·
Forward Clutch Stall Speed
Application Min. Max.
3.8L engine 2,240 2,619
4.6L 2V engine 2,339 2,738
4.6L 4V MACH 1 engine 2,375 2,767 Klj . 4 ba
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