2003 FORD MUSTANG check engine

mechanism damaged
Main Controls
·
Manual valve stuck or
damaged ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications.
Other Concerns: External Leaks Possible Component Reference/Action
252 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, sensor
seals leaking (digital TR, OSS,
vehicle speed sensor VSS, if
equipped, or transmission connector) ·
Inspect for leakage and repair as required. 352 —
HYDRAULIC/MECHANICAL ROUTINE Case
·
Case vent, case porosity, case
cracked ·
Check the vent for free breathing. Check the fluid level.
Check the transmission for overheat conditions. Repair
as required. Seals/Gaskets
·
Leakage at gaskets, seals, etc. (refer
to external sealing illustration for
potential leak locations) ·
Remove all traces of lubricant on exposed surfaces of
the transmission. Check the vent for free breathing.
Operate the transmission at normal temperatures and
perform fluid leakage check. Repair as required. Other
·
Cooler fitting, cooler lines pressure
tap, converter drain plug, band
anchor pins ·
Locate the source of the leak. Repair as required.
Other Concerns: Poor Vehicle Performance Possible Component Reference/Action
253 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, shift solenoids,
digital TR sensor, torque
converter clutch (TCC) solenoid,
transmission fluid temperature
(TFT) sensor ·
Carry out Self-Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for diagnosis
and testing of the Powertrain Control System. Go To Pinpoint Test A ,
Go To Pinpoint Test B or
Go To Pinpoint Test C . Repair as required. Clear codes, road test and
repeat Self- Test. Also refer to Routines 241/341 Torque
Converter Operation Concern: Always Applied. ·
Engine driveability concerns ·
Inspect air intake/air filter system. Check the fuel system
and fuel pressure. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual. Inspect the
exhaust system for restriction. Refer to Section 309 - 00 .
353 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR Sensor Klj . 27 ba
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4. Use only clean automatic transmission fluid.
5. Once the fluid exchange has been completed, disconnect the flush and fill machine. Reconnect
any disconnected fluid cooler tubes.
6. With the engine running and the transmission at normal operating temperature 66- 77°C (150-
170°F), check and adjust the transmission fluid level, and check for any leaks. If fluid is needed,
add fluid in increments of 0.24- liter (0.5-pint) until the correct level is achieved (fluid should be in
the cross- hatched area of the fluid level indicator).
Draining
Vehicles equipped with a torque converter drain plug 1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100 - 02 .
2. Loosen the transmission fluid pan bolts and allow the fluid to drain.
3. After the fluid has drained, remove the transmission fluid pan.
4. Do not remove the fluid filter. It is not necessary to change the fluid filter during a normal maintenance fluid change.
5. Remove the torque converter drain plug cover. Klj . 2 ba
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10. Install the torque converter drain plug cover.
11. Position the magnet into the transmission fluid pan.
12.
NOTE: The fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the
gasket should be reused.
Install the fluid pan and gasket. 1. Position the fluid pan with the gasket in place.
2. Install the bolts.
13. CAUTION: The use of any other transmission fluid can result in the transmission
failing to operate in a normal manner or transmission failure.
Fill the transmission.
zAdd 4.7 liters (5 qts) of clean automatic transmission fluid to the transmission through the
fluid filler tube.
14. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements.
15. With the engine running and the transmission at normal operating temperature 66- 77°C (150- Klj . 4 ba
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Refill
7. Position the magnet into the transmission fluid pan.
8. NOTE: The fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the
gasket should be reused.
Install the fluid pan and gasket.
1. Position the fluid pan with the gasket in place.
2. Install the bolts.
9. CAUTION: The use of any other transmission fluid can result in the transmission
failing to operate in a normal manner or transmission failure.
Fill the transmission.
zAdd 4.7 liters (5 qts) of clean automatic transmission fluid to the transmission through the
fluid filler tube.
10. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements.
11. With the engine running and the transmission at normal operating temperature 66- 77°C (150-
170°F), check and adjust the transmission fluid level, and check for any leaks. If fluid is needed,
add fluid in increments of 0.24- liter (0.5-pint) until the correct level is achieved (fluid should be in
the cross- hatched area of the fluid level indicator). Klj . 6 ba
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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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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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z
Excessive noise zPilot bearing
worn or
damaged.
z Excessive
crankshaft end
play. z
Go To Pinpoint Test G .
z Transmission difficult to
shift z
Lubricant. zADD or DRAIN AND
FILL with specified
lubricant.
z Internal shift
mechanism. z
CHECK the internal shift
mechanism for smooth
operation. REPAIR or
INSTALL a new
mechanism as
necessary.
z Sliding gears,
synchronizers. z
CHECK for free
movement of gears and
synchronizers. REPAIR
or INSTALL new
components as
necessary.
z Housings, shaft. zCHECK for binding
condition between the
input shaft and the
engine crankshaft pilot
bearing or bushing.
REPAIR or INSTALL
new components as
necessary. REFER to
Section 308 - 03A or
Section 308 - 03B .
z Loose pressure
plate to flywheel
bolts. z
CHECK for loose bolts
at the pressure plate.
INSTALL new
components as
necessary. REFER to
Section 308 - 01 .
z NOTE: While verifying
the condition, determine
whether the noise is gear
rollover noise, release
bearing rub or some
other transmission-
related noise. Gear
rollover noise, inherent in
manual transmissions, is
caused by the constant
mesh gears turning at the
engine idle speed while
the clutch is engaged and
the transmission is in
NEUTRAL. Release
bearing rub is sometimes
mistaken for mainshaft
bearing noise. Gear
rollover noise will
disappear when the
clutch is disengaged or
when the transmission is
engaged in gear. z
Lubricant. zADD or DRAIN AND
FILL with specified
lubricant. Klj . 3 ba
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Release bearing rub will
disappear when the
clutch is engaged. In the
event that a bearing is
damaged, the noise is
more pronounced while
engaged in gear under
load or coast than in
NEUTRAL.
Noisy in forward gears
zComponents
grounding out
on the
transmission. z
CHECK for screws,
bolts, etc., of body or
other components
grounding out.
CORRECT as
necessary.
z Components
housing bolts. z
CHECK the torque on
the transmission-to-
flywheel housing bolts
and the flywheel
housing- to-engine block
bolts. TIGHTEN the
bolts to specification.
REFER to Section 308 -
01 .
z Bearings or
gears. z
INSPECT the bearings.
INSPECT the gears and
gear teeth for wear or
damage. INSTALL new
components as
necessary. REFER to
Section 308 - 01 .
z Gears clash when
shifting from one forward
gear to another z
Pilot bearing. zCHECK for a binding
condition between the
input shaft and the
engine crankshaft pilot
bearing. INSTALL new
components as
necessary. REFER to
Section 308 - 01 .
z Gear teeth
and/or
synchronizer. z
REPAIR or INSTALL
new components as
necessary. REFER to
Section 308 - 03A or
Section 308 - 03B .
z Engine idle
speed too high. z
REFER to the
Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
z Transmission jumps out
of gear z
Transmission
range selector
lever boot. z
INSTALL a new boot if
exceptionally stiff.
REFER to Section 308 -
03A or
Section 308 -
03B .
z Transmission-to-
engine mounting
bolts. z
TIGHTEN the bolts to
specification. Klj . 4 ba
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