2003 FORD MUSTANG suspension

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. Disconnect the suspension upper arm and bushing at the knuckle. Discard the nut and the bolt. Klj . 3 ba
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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. Position the tie- rod link in the knuckle.
2. Install a new nut.
3. Install a new cotter pin.
9. Raise the suspension until the shock absorber is compressed to the previously established alignment mark (curb height). Klj . 7 ba
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10. Connect the shock absorber to the suspension lower arm and bushing and install the new bolt
and a new nut.
11. Tighten the nut.
12. Lower the suspension and remove the jack stand.
13. Apply Anti- Seize Lubricant to the rear brake anti- lock sensor where it contacts the axle housing
and install the anti- lock sensor.
z Use High Temperature Nickel Anti- Seize Lubricant F6AZ-9L494-AA or equivalent
meeting Ford specification ESE-M124A- A.
14. Install the rear brake disc. For additional information, refer to Section 206 - 04 .
15. Tighten the retainer. Klj . 8 ba
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For low or spongy brake pedal concerns:
zcheck and, if necessary, refill the brake master cylinder reservoir.
z bleed the brake system and retest the brake pedal feel.
z if the brake pedal is still low or feels spongy, check the brake pedal mounting for looseness and
correct installation. Check the power brake booster and the brake master cylinder for loose
mounting. Correct as necessary and retest the system for normal operation.
For a slow or incomplete brake pedal return concern:
zinspect for binding, damage, correct installation or interference at the brake pedal.
z check the power brake booster for binding, damage and correct installation.
Vibration When Brakes are Applied
For vibration concerns when brakes are applied, perform the following procedure.
Visually inspect: ztire condition and pressure.
z suspension bushings and ball joints.
Correct as necessary. 1. Verify and isolate the concern. Brake roughness can be felt in: zthe steering wheel.
z the seat.
z the brake pedal.
2. After verifying the concern, check for related concerns in the: zOn- Line Automotive Service Information System (OASIS).
z Technical Service Bulletins.
3. Check wheel bearing end- play and correct as necessary.
4. NOTE: Begin at the front of the vehicle unless the vibration has been isolated to the rear.
Remove the tire and wheel.
5. Remove the brake caliper.
6. Measure and record the brake disc thickness. Install a new brake disc if the thickness after machining will be at or below specification. The specification is molded into the brake disc. Do z
Power brake booster
z Brake pedal linkage
z Vacuum booster hose
z Tires
z Foreign material Klj . 3 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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9. If an obvious cause for an observed or reported malfunction is found, correct the cause (if
possible) before proceeding to the next step.
10. If the fault is not visually evident, determine the symptom and proceed to the following symptom chart.
Steering System Symptom Definitions
Drift/Pull
Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the
vehicle going straight.
Drift describes what a vehicle with this condition does with hands off the steering wheel.
zA vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-
ahead path and require constant steering input in the opposite direction to counteract the effect.
z Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber).
Excessive Steering Wheel Play
Excessive steering wheel play is a condition in which there is too much steering wheel movement
before the wheels move. A small amount of steering wheel free play is considered normal.
Feedback
Feedback is a roughness felt in the steering wheel when the vehicle is driven over rough pavement.
Hard Steering or Lack of Assist
Hard steering or lack of assist is experienced when the steering wheel effort exceeds specifications.
Hard steering can remain constant through the full turn or occur near the end of a turn. It is important
to know the difference between hard steering/lack of assist and binding.
Hard steering or lack of assist can result from either hydraulic or mechanical conditions. It is extremely
important to know if this concern occurs during driving, during very heavy or static parking maneuvers.
Nibble
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road
surfaces and observed by the driver as small rotational oscillations of the steering wheel. Poor Returnability/Sticky Steering Visual Inspection Chart
Mechanical
z
Loose tie- rod ends
z Loose suspension components
z Loose steering column shaft universal joints
z Loose column intermediate shaft bolts
z Steering gear
z Binding or misaligned steering column
z Power steering pump
z Bent or pinched power steering hoses Klj . 4 ba
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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.
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.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel
corrections to maintain a straight path down a level road.
Symptom Chart
Symptom Chart Condition
Possible Sources Action
z Hard Steering or
Lack of Assist z
Seized lower steering
column shaft U- joints. z
INSTALL a new lower
steering column shaft.
REFER to Section 211 - 04 .
z Damaged, fractured
steering column
bearing(s). z
REPAIR the steering
column. REFER to
Section 211 - 04 .
z Power steering pump. zGO to Pump Flow and
Pressure Test
Component Test in
this section.
z Suspension
components. z
REFER to Section 204 - 00 for suspension
system diagnosis and
testing.
z Steering gear internal
leakage. z
GO to Pump Flow and
Pressure Test
Component Test in
this section.
z Excessive Steering
Pump Noise z
Power steering pump. zGO to Pump Flow and
Pressure Test
Component Test in
this section.
z Excessive Steering
Wheel Play z
Damaged, loose, or
worn tie- rod end
(3A130). z
GO to the Steering
Linkage Component
Test.
z Loose, worn or
damaged front wheel
spindle tie- rod (3280). z
GO to the Tie- Rod
Articulation Torque
Component Test.
z Damaged/worn
steering gear. z
INSTALL a new
steering gear. REFER
to Section 211 - 02 .
z Loose, worn or
damaged steering z
INSTALL new
steering column Klj . 5 ba
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column bearing(s).
bearing(s). REFER to
Section 211 - 04 .
z Loose, worn or
damaged lower
steering column shaft
U-joint(s). z
INSTALL a new lower
steering column shaft.
REFER to Section 211 - 04 .
z Wander zUnevenly loaded or
overloaded vehicle. z
INFORM the
customer of incorrect
vehicle loading.
z Loose, worn or
damaged front wheel
spindle tie- rod. z
GO to the Tie- Rod
Articulation Torque
Component Test.
z Loose, worn or
damaged tie- rod ends. z
GO to the Steering
Linkage Component
Test.
z Loose or damaged
steering gear mounting
bolts. z
INSTALL new or
TIGHTEN bolts.
REFER to Section 211 - 02 .
z Loose lower steering
column shaft U- joint
bolts. z
TIGHTEN the bolts.
REFER to Section 211 - 04 .
z Loose, worn or
damaged lower
steering column shaft
U-joints. z
INSTALL a new lower
steering column shaft.
REFER to Section 211 - 04 .
z Loose, worn or
damaged steering
column bearing(s). z
INSTALL new
steering column
bearings. REFER to
Section 211 - 04 .
z Suspension
components. z
REFER to Section 204 - 00 for suspension
system diagnosis and
testing.
z Drift/Pull zUnevenly loaded or
overloaded vehicle. z
INFORM the
customer of incorrect
vehicle loading.
z Wheel alignment. zCHECK the wheel
alignment. ADJUST
as required. REFER
to Section 204 - 00 .
z Loose, worn or
damaged front wheel
spindle tie- rod. z
GO to the Tie- Rod
Articulation Torque
Component Test.
z Loose, worn or
damaged tie- rod ends. z
GO to the Steering
Linkage Component
Test.
z Suspension
components. z
REFER to Section 204 - 00 for suspension
system diagnosis and
testing.
z The steering gear valve
effort out of balance. z
GO to Steering Gear
Valve Component
Test in this section.
z Check the brake
system for proper z
REFER to Section 206 - 00 . Klj . 6 ba
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