2003 FORD MUSTANG manual transmission

vehicle wiring harnesses,
PCM, shift solenoids,
OSS Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Go To Pinpoint Test A or
Go To Pinpoint Test E . Repair as required. Clear DTCs, road test and
repeat Self- Test. ·
Poor engine performance ·
Refer to Routine 253. 320 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR
Sensor
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift cable
as necessary. After repairing transmission shift cable, verify that the
digital TR sensor is correctly adjusted. Adjust the digital TR sensor
as necessary. Incorrect Pressures
·
Intermediate clutch
pressure, line pressure ·
Check pressure at line and intermediate clutch taps; see the line
pressure chart for specifications. If not OK, check the main controls. Main Controls
·
1- 2 shift valve, stuck or
damaged ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specification. ·
Shift solenoid SSA
malfunction ·
Activate solenoid using scan tool. If solenoid operation cannot be
felt when placing hand on solenoid, install a new solenoid. Inspect
O- rings for damage. Repair as required. ·
Gasket damaged ·
Inspect for damage and install a new gasket. ·
No. 8 ball not seating ·
Inspect for damage. Repair as required. Case
·
1- 2 accumulator stuck or
damaged ·
Inspect for damage. Repair as required. Pump
·
Porosity/cross leaks,
balls missing, damaged
or leaking ·
Inspect for porosity/leaks, balls missing. Install a new pump as
required. ·
Gasket damaged ·
Inspect for damage and install a new gasket. Intermediate Clutch
Assembly
·
Seals damaged ·
Inspect for damage. Repair as required. ·
Piston damaged ·
Inspect for damage. Repair as required. ·
Friction elements
damaged or worn ·
Inspect for damage. Repair as required. Intermediate One-
Way
Clutch Assembly ·
Not holding or damaged ·
Inspect for damage. Repair as required. Planetary One-
Way Clutch
Assembly ·
Not overrunning or
damaged ·
Inspect for damage. Repair as required. 1-
2 Accumulator ·
Damaged accumulator ·
Inspect for damage. Repair as required. Klj . 17 ba
312003 Mustang Workshop Manual
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piston
·
Springs damaged or
broken ·
Inspect for damage. Repair as required. ·
Case bore scored ·
Inspect for damage. Repair as required.
Shift Concerns: 2-3 Shift (Automatic) Possible Component Reference/Action
221 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, shift solenoids, OSS ·
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 or
Go To Pinpoint Test E . Repair as required. Clear DTCs, road test
and repeat Self- Test. ·
Engine driveability concerns ·
Refer to Routine 253. 321 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment. Refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable,
verify that the digital TR sensor is correctly adjusted. Adjust the
digital TR sensor as necessary. Incorrect Pressures
·
Direct clutch pressure ·
Check pressure at direct clutch tap; refer to Line Pressure
Chart for specifications. If not OK, check the main controls. Main Controls
·
2- 3 shift valve, check ball No.
9 or No. 3, solenoid pressure
regulator valve, damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Shift solenoid SSB
malfunction ·
Activate solenoid using scan tool. If solenoid operation cannot
be felt when placing hand on solenoid, install a new solenoid.
Inspect O- rings for damage. Repair as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
Output shaft seals damaged
or cup plug leaking or missing ·
Inspect for damage and repair as required. ·
2- 3 accumulator damaged or
stuck ·
Inspect piston seal and bore for damage. Repair as required. ·
Solenoid screen (in main
control) blocked or damaged ·
Clean or install a new screen. Intermediate One-
Way Clutch
Assembly ·
Not overrunning or damaged ·
Inspect for damage. Repair as required. Output Shaft
·
Seal rings damaged ·
Inspect for damage. Repair as required. ·
Cup plug damaged or missing Klj . 18 ba
312003 Mustang Workshop Manual
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Direct Clutch Assembly
·
Seals or piston damaged ·
Inspect for damage. Repair as required. ·
Friction elements worn or
damaged ·
Inspect for damage. Repair as required. ·
Check ball not seating ·
Inspect for damage. Repair as required. ·
Return spring assembly
damaged ·
Inspect for damage. Repair as required. Case
·
Output shaft rear seals
leaking or damaged ·
Inspect for damage. Repair as required. Inspect case for
damaged seal area. If damaged, install a new case. 2-
3 Accumulator ·
Damaged accumulator piston ·
Inspect for damage. Repair as required. ·
Springs damaged or broken ·
Inspect for damage. Repair as required. ·
Case bore scored ·
Inspect for damage. Repair as required.
Shift Concerns: 3-4 Shift (Automatic) Possible Component Reference/Action
222 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, shift
solenoids, OSS, transmission
control switch (TCS) ·
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 or
Go To Pinpoint Test E . Repair
as required. Clear DTCs, road test and repeat Self- Test. ·
Engine driveability concerns ·
Refer to Routine 253. 322 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR Sensor
·
Damaged or incorrectly adjusted ·
Inspect and repair as required. Verify transmission shift
cable adjustment; refer to Section 307 - 05 . Adjust
transmission shift cable as necessary. After repairing
transmission shift cable, verify that the digital TR sensor
is correctly adjusted. Adjust the digital TR sensor as
necessary. Incorrect Pressures
·
Forward clutch pressure, direct
clutch pressure, line pressure ·
Check line, direct and forward clutch pressures at
appropriate taps; refer to Line Pressure Chart for
specifications. If pressures are out of specification, check
main controls. Main Controls
·
3- 4 shift valve, solenoid pressure
regulator valve, OD servo regulator,
3- 4 capacity modulator valve, 1- 2
and 2- 3 shift valves stuck, damaged
or assembled incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to specifications ·
Tighten bolts to specifications. ·
SSA or SSB malfunction ·
Activate solenoid using scan tool. If solenoid operation
cannot be felt when placing hand on solenoid, install a
new solenoid. Inspect O- rings for damage. Repair as Klj . 19 ba
312003 Mustang Workshop Manual
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required.
·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
OD servo rod and piston cushion
spring or seals damaged ·
Inspect for damage. Repair as required. ·
Worn or damaged OD servo anchor
pins ·
Inspect for damage. Repair as required. ·
No. 2, No. 4, No. 7 and No. 9 check
balls damaged or missing ·
Inspect for damage. Repair as required. ·
Solenoid screen blocked or
damaged ·
Clean or install a new screen. Pump
·
Porosity/cross leaks, balls missing,
damaged or leaking ·
Inspect for porosity/leaks, balls missing. Install a new
pump as required. ·
Gaskets damaged ·
Inspect for damage. Install new gaskets as required. OD Band
·
OD band and reverse clutch drum
assembly damaged, worn or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
Intermediate one- way clutch
assembly damaged ·
Inspect for damage. Repair as required. Forward Clutch Assembly
·
Seals or piston damaged ·
Inspect for damage. Repair as required. ·
Friction elements worn or damaged ·
Inspect for damage. Repair as required. ·
Check ball stuck, damaged or not
seating correctly ·
Inspect for damage. Repair as required. Input Shaft
·
Seals damaged ·
Inspect for damage. Repair as required.
Shift Concerns: 4-3 Shift (Automatic) Possible Component Reference/Action
223 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle wiring
harnesses, PCM, shift solenoids,
transmission control switch (TCS) ·
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 . Repair as required.
Clear DTCs, road test and repeat Self- Test. 323 —
HYDRAULIC/MECHANICAL ROUTINE Incorrect Pressures
·
Forward clutch pressure, line pressure ·
Check line and forward clutch at pressure taps; refer to
Line Pressure Chart for specifications. If out of
specification, check the main controls. Main Controls
·
3- 4 shift valve, solenoid pressure
regulator valve, OD servo regulator, 3-
4 capacity modulator, 1- 2 and 2-3 shift
valves stuck, damaged or assembled ·
Inspect for damage. Repair as required. Klj . 20 ba
312003 Mustang Workshop Manual
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Pump
·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
Porosity/cross leaks ·
Inspect for leak/porosity. Install a new pump as required. Intermediate Clutch Assembly
·
Piston damaged ·
Inspect for damage. Repair as required. ·
Friction elements damaged,
worn ·
Inspect for damage. Repair as required. ·
End clearance incorrect ·
Inspect and correct; refer to Transmission Assembly. Intermediate One-
Way Clutch ·
Damaged ·
Inspect for damage. Repair as required. ·
Intermediate one- way clutch
retaining snap ring not seated ·
Inspect for damage. Repair as required. Planetary One-
Way Clutch ·
Not holding or damaged ·
Inspect for damage. Repair as required.
Torque Converter Clutch Operation Concerns: No Apply Possible Component Reference/Action
240 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, torque
converter clutch (TCC) solenoid, TFT
sensor, OSS ·
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 B or
Go To Pinpoint Test E .
Repair as required. Clear codes, road test and repeat
Self- Test. 340 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage
·
Damaged or incorrectly adjusted ·
Inspect and repair as required. Verify transmission shift
cable adjustment; refer to Section 307 - 05 . Adjust
transmission shift cable as necessary. After repairing
transmission shift cable, verify that the digital TR
sensor is correctly adjusted. Adjust the digital TR
sensor as necessary. Incorrect Pressures
·
Low line pressure, low EPC pressure ·
Check pressure at line and EPC taps; refer to Line
Pressure Chart for specifications. If pressure is low,
check EPC and main regulator valve. If within
specifications, check the main controls. Main Controls
·
Solenoid pressure regulator valve,
manual valve, bypass clutch control
valve and plunger, converter
pressure limit valve, drain back valve
stuck, damaged or assembled
incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to specifications ·
Tighten bolts to specifications. ·
Solenoid screen blocked or damaged ·
Clean or install a new screen. ·
TCC solenoid malfunction ·
Activate solenoid using scan tool. If solenoid operation Klj . 23 ba
312003 Mustang Workshop Manual
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·
No end clearance ·
Inspect converter and install a new or remanufactured torque
converter as required. ·
Piston plate damaged or stuck
to cover ·
If cover is heat- stained, install a new converter and determine
the cause of the overheat condition.
Torque Converter Clutch Operation Concerns: Cycling/Shudder/Chatter Possible Component Reference/Action
242 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, torque
converter clutch (TCC) solenoid,
OSS ·
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 E . Repair as required. Clear
DTCs, road test and repeat Self- Test. ·
Speed control equipped vehicles ·
Evaluate with speed control off. 342 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Condition ·
Inspect fluid condition. If burnt, drain fluid and converter.
Install a new fluid and filter assembly. Bring vehicle to
normal operating temperature. Carry out Transmission
Drive Cycle Test. Carry out Transmission Self- Test. If
condition still exists, continue diagnostics. Main Controls
·
Solenoid pressure regulator valve,
No. 7 check ball, bypass clutch
control valve and plunger, converter
pressure limit valve stuck, damaged
or assembled incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to specifications ·
Tighten bolts to specifications. ·
Solenoid screen blocked or damaged ·
Clean or install a new screen. ·
TCC solenoid malfunction ·
Activate solenoid using scan tool. If solenoid operation
cannot be felt when placing hand on solenoid, install a
new solenoid. Inspect O- rings for damage. Repair as
required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Pump Assembly
·
Bolts not tightened to specification ·
Tighten bolts to specification. ·
Porosity/cross leaks, missing balls or
leaking ·
Inspect for porosity/leaks or missing balls. Install a new
pump as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Input Shaft
·
Seals damaged ·
Inspect for damage. Repair as required. Torque Converter
·
Excessive end clearance ·
Inspect converter. Install a new or re- manufactured
torque converter as required.
Other Concerns: No Engine Braking In Manual 2nd Or Manual 1st Position Klj . 25 ba
312003 Mustang Workshop Manual
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Possible Component Reference/Action
250 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 350 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable,
verify that the digital TR sensor is correctly adjusted. Adjust
the digital TR sensor as necessary. Main Controls
·
3- 4 shift valve, 1- 2 and 2-3
shift valve, gaskets, 3-4
capacity modulator valve,
stuck or damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
OD servo assembly damaged
or stuck in manual 2nd only. ·
Inspect cover, piston and seal for damage. Repair as required. ·
Low/Reverse servo assembly
damaged or stuck in manual
1st only ·
Inspect cover, piston and seal for damage. Repair as required. Overdrive
·
Reverse band, manual 1st
(only) damaged ·
Inspect for damage. Repair as required. ·
OD band, reverse clutch drum
assembly worn or damaged
(manual 2nd only) ·
Inspect for damage. Repair as required. Reverse Band (Manual 1st Only)
·
Damaged or incorrectly
adjusted ·
Inspect for damage. Repair as required.
Other Concerns: Shift Lever Efforts High Possible Component Reference/Action
251 —
ELECTRICAL ROUTINE ·
No Electrical Concerns 351 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR
Sensor
·
Damaged or incorrectly
adjusted ·
Inspect and repair as required. Verify transmission shift cable
adjustment; refer to Section 307 - 05 . Adjust transmission shift
cable as necessary. After repairing transmission shift cable, verify
that the digital TR sensor is correctly adjusted. Adjust the digital
TR sensor as necessary. ·
Brake shift interlock
system, solenoid damaged ·
Refer to the appropriate brake section in the workshop manual. Manual Lever
·
Retaining pin damaged, nut
loose, detent spring bent or
damaged or Park ·
Inspect for damage. Repair as required. Klj . 26 ba
312003 Mustang Workshop Manual
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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
312003 Mustang Workshop Manual
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