2003 FORD MUSTANG ABS

6. For vehicles with a two-
piece hub and brake disc assembly:
z Match-mark before disassembly.
z Remove the brake disc.
z Clean the hub and brake disc mounting surfaces with metal surface cleaner.
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.
7. 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 an on- car brake lathe, machine the brake discs. Follow the manufacturer's instructions.
After machining, make sure the brake disc still meets the thickness specification.
8. Using the special tools, verify that the brake disc lateral runout is now within specification. For additional information, refer to Section 206 - 00 .
9. Remove the special tool hub adapter.
10. Remove any remaining metal chips from the machining operation.
11. For vehicles with a two- piece hub and 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 a liberal amount of lubricant to the hub flange, pilot area and to the brake disc- to-
hub mounting surface.
z Using the match marks, mount the brake disc on the hub.
12. Install the brake caliper anchor plate and the brake caliper.
13. Install the tire and wheel assembly.
14. Test the system for normal operation. Klj . 2 ba
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DIAGNOSIS AND TESTING
Suspension System
Inspection and Verification
1. Road test. zVerify the customer's concern by performing a road test on a smooth road.
2. Inspect tires. zCheck the tire pressure with all normal loads in the vehicle and the tires cold. For
additional information, refer to the vehicle certification (VC) label.
z Verify that all tires are sized to specification.
z Inspect the tires for incorrect wear and damage.
3. Inspect chassis and underbody. zRemove any excessive accumulation of mud, dirt or road deposits from the chassis and
underbody.
4. Inspect for aftermarket equipment. zCheck for aftermarket changes to the steering, suspension, wheel and tire components
(such as competition, heavy duty, etc.) The specifications shown in this manual do not
apply to vehicles equipped with aftermarket equipment.
5. Inspect shock absorbers. All vehicles are equipped with gas- pressurized hydraulic shock absorbers. These shock
absorbers are not adjustable or refillable and cannot be repaired.
zOil Leak: A light film of oil (weepage) on the upper portion of the shock absorber is
permissible and is a result or correct shock lubrication. Weepage is a condition in which a
film of oil accumulates on the thin tube (body) and is normally noticed due to the
collection of dust in this area. If shock absorbers exhibit this weepage condition, they are
functional units and new shock absorbers should not be installed. Leakage is a condition
in which the entire shock absorber body is covered with oil and the oil will drip from the
shock absorber onto the pavement. If condition exists:
„Make sure fluid observed is not from sources other than the shock absorber.
„ Install a new shock absorber, if necessary.
z Vehicle Sag: Many times new shock absorbers are installed in an effort to solve a vehicle
sag concern. Shock absorbers by design are hydraulic damping units only and, unlike
suspension springs, do not support any suspension loads. Therefore, installing a new
shock absorber will not correct a vehicle sag concern.
z Installment in Pairs: In the past it was recommended that new shock absorbers be
installed in pairs if one unit became unrepairable. New shock absorbers no longer need
to be installed in pairs when only one unit is not repairable.
SECTION 204-
00: Suspension System — General Information 2003 Mustang Workshop Manual Visual Inspection Chart
Mechanical Klj . 1 ba
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6. If an obvious cause for an observed or reported condition is found, correct the cause (if
possible) before proceeding to the next step.
7. If the fault is not visually evident, determine the symptom and GO to Symptom Chart .
Symptom Chart z
Front wheel bearing(s)
z Loose or damaged front or rear suspension components
z Loose, damaged or missing suspension fastener(s)
z Damaged spring(s)
z Damaged or leaking strut and spring assemblies
z Damaged or leaking shock absorber(s)
z Worn or damaged suspension bushing(s)
z Loose, worn or damaged steering system components
z Damaged axle components
Symptom Chart Condition
Possible Sources Action
z Dogtracking zExcessive rear
thrust angle. z
CHECK the wheel alignment.
ADJUST as necessary.
z Front or rear
suspension
components. z
INSPECT the front and rear
suspension system. REPAIR
or INSTALL new suspension
components as necessary.
REFER to Section 204 - 01 or
Section 204 - 02 .
z Drive axle
damaged. z
REPAIR as necessary. Refer
to the appropriate section in
Group 205 for the procedure..
z Drift/pull zUnequal tire
pressure. z
ADJUST tire pressure.
z Excessive side-to-
side difference in
caster or camber. z
CHECK the wheel alignment.
ADJUST as necessary.
z Tire forces. zROTATE tires front to rear.
z Unevenly loaded or
overloaded vehicle. z
NOTIFY the customer of
incorrect vehicle loading.
z Steering
components. z
REFER to Section 211 - 00 .
z Brake drag. zREFER to Section 206 - 00 .
z Front bottoming
or riding low z
Strut(s). zINSTALL new strut(s) as
necessary. REFER to Section 204 - 01 .
z Front coil springs
(5310). z
CHECK ride height. INSTALL
new springs as necessary.
REFER to Section 204 - 01 .
z Incorrect tire
wear z
Incorrect tire
pressure (rapid
center rib or inner
and outer edge
wear). z
ADJUST tire pressure. Klj . 2 ba
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z
Excessive front or
rear toe (rapid inner
or outer edge
wear). z
CHECK the wheel alignment.
ADJUST as necessary.
z Excessive negative
or positive camber
(rapid inner or outer
edge wear). z
CHECK the wheel alignment.
ADJUST as necessary.
z Tires out of balance
(tires cupped or
dished). z
BALANCE tires.
z Rough ride zStrut(s). zINSTALL new strut(s) as
necessary. REFER to Section 204 - 01 .
z Shock absorber(s). zINSTALL new shock absorber
(s) as necessary.
z Front coil springs or
rear springs (5560). z
INSTALL new front coil
springs or rear springs as
necessary. REFER to Section 204 - 01 or
Section 204 - 02 .
z Shimmy or
wheel tramp z
Loose wheel nut(s). zTIGHTEN to specification.
REFER to Section 204 - 04 .
z Loose front
suspension
fasteners. z
TIGHTEN to specification.
REFER to Section 204 - 01 .
z Front wheel bearing
(s). z
REFER to Wheel Bearing Inspection in this section.
z Wheel or tire
runout. z
REFER to Section 204 - 04 .
z Tire flatspotting. zREFER to Section 204 - 04 .
z Shock absorber(s). zINSTALL new shock absorber
(s) as necessary.
z Loose, worn or
damaged ball joint
(s). z
GO to the Ball Joint Inspection
component test in this section.
z Loose, worn or
damaged steering
components. z
REFER to Section 211 - 00 .
z Front wheel
alignment. z
CHECK the wheel alignment.
ADJUST as necessary.
z Sticky steering,
poor returnability z
Ball joints. zGO to the Ball Joint Inspection
component test in this section.
z Steering
components. z
REFER to Section 211 - 00 .
z Steering wheel
off- center z
Unequal front or
rear toe settings
(side-to- side). z
CHECK the wheel alignment.
ADJUST as necessary.
z Steering
components. z
REFER to Section 211 - 00 .
z Sway or roll zOverloaded,
unevenly or
incorrectly loaded
vehicle. z
NOTIFY the customer of
incorrect vehicle loading.
z Loose wheel nut(s). zTIGHTEN to specification. Klj . 3 ba
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REFER to
Section 204 - 04 .
z Strut(s). zINSTALL new strut(s) as
necessary. REFER to Section 204 - 01 .
z Shock absorber(s). zINSTALL new shock absorber
(s) as necessary.
z Loose front
stabilizer bar (5482)
or rear stabilizer
bar (5A772). z
TIGHTEN to specification.
REFER to Section 204 - 01 or
Section 204 - 02 .
z Worn stabilizer
assembly bushing
(s). z
INSTALL new bushing(s) as
necessary. REFER to Section 204 - 01 or
Section 204 - 02 .
z Front coil spring(s)
or rear spring(s). z
INSTALL new front coil
springs or rear springs as
necessary. REFER to Section 204 - 01 or
Section 204 - 02 .
z Vehicle leans to
one side z
Unevenly loaded or
overloaded vehicle. z
NOTIFY the customer of
incorrect vehicle loading.
z Front or rear
suspension
components. z
INSPECT the front and rear
suspension system. REPAIR
or INSTALL new suspension
components as necessary.
REFER to Section 204 - 01 or
Section 204 - 02 .
z Front coil springs or
rear springs. z
INSTALL new front coil
springs or rear springs as
necessary. REFER to Section 204 - 01 or
Section 204 - 02 .
z Incorrect ride
height. Lateral tilt
out of specification. z
CHECK ride height. INSTALL
new front coil springs or rear
springs as necessary. REFER
to Section 204 - 01 or
Section 204 - 02 .
z Vibration/noise zTire or wheel
runout.
z Tire flatspotting.
z Wheel bearings.
z Wheel hubs.
z Brake components.
z Suspension
components.
z Steering
components. z
REFER to Section 100 - 04 .
z Wander zUnevenly loaded or
overloaded vehicle. z
NOTIFY the customer of
incorrect vehicle loading.
z Ball joint(s). zGO to the Ball Joint Inspection
component test in this section.
z Front wheel bearing
(s). z
REFER to Wheel Bearing Inspection in this section.
z Loose, worn or
damaged
suspension
components(s). z
INSTALL new suspension
components as necessary.
REFER to Section 204 - 01 or
Section 204 - 02 .
z Loose suspension
fasteners. z
TIGHTEN to specification.
REFER to Section 204 - 01 or
Section 204 - 02 . Klj . 4 ba
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GENERAL PROCEDURES
Camber and Caster Adjustment —
Front
All vehicles 1. Remove the rivet. Loosen the nuts and bolt.
Vehicles requiring camber adjustment 2. Move the front suspension camber adjusting plate (3B391) to the required camber setting.
Vehicles requiring caster adjustment 3. NOTE: If caster adjustment is necessary to resolve a pull, or out of specification cross- caster
split, then slotting the shock tower at the front shock absorber (18124) upper mounting point is
an acceptable method. This procedure should not be routinely performed with all alignments
and only after all other possible sources have been inspected and corrected as necessary.
Determine the amount of caster adjustment needed.
zIf no more than 0.6 degree is needed, only one shock tower needs to be slotted.
4. Mark the camber position of the front suspension camber adjusting plate (3B391).
SECTION 204-
00: Suspension System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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5. Remove the nuts, bolt and the front suspension camber adjusting plate.
6. Raise the front end. Position the strut and spring assembly out of the way. For additional
information, refer to Section 100 - 02 .
7. Cut slots perpendicular to the existing camber adjustment slots. zMoving the top of the front shock absorber toward the rear of the vehicle will increase the
caster reading for that side.
z Each millimeter of adjustment should yield approximately 0.12 degree of caster change.
z Do not cut slots any longer than 5 mm (0.2 in.) in any direction.
z Remove any burrs.
z Clean and paint any exposed metal.
8. Position the strut and spring assembly. Lower the front end.
9. Install the front suspension camber adjustment plate, bolt and nuts. Hand tighten the bolt and nuts. Klj . 2 ba
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SPECIFICATIONS
SECTION 204-
01: Front Suspension 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft lb-
in Front shock absorber upper nut 100 74 —
Front shock absorber-
to-spindle nuts 200 148 —
Shock absorber upper mount-
to-body nuts 40 30 —
Shock absorber upper mount-
to-body bolt 40 30 —
Wheel hub and bearing retainer nut 350 258 —
Stabilizer bar bracket nuts 70 52 —
Stabilizer bar link nuts 19 14 —
Anti-
lock brake sensor bolt 6 — 53
Anti-
lock brake sensor wire bracket nut 28 21 —
Ball joint-
to-front wheel spindle nut 175 129 —
Front suspension lower arm-
to-body nuts 200 148 —
Tie-
rod- to-spindle nuts 55 41 —
Steering gear-
to-crossmember nuts 70 52 —
Wheel nuts 129 95 — Klj . 1 ba
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