2003 FORD MUSTANG belt

surfaces
zYoke spring in the
steering gear. z
CHECK TSBs for
revised yoke spring for
applicable vehicles.
z Accessory drive
belt squeal/chirp—
when rotating the
steering wheel
from stop to stop z
Loose or worn
accessory drive belt. z
ADJUST or INSTALL a
new accessory belt as
necessary. REFER to
Section 303 - 05 .
z Power steering
gear hiss z
Steering column
intermediate/flexible
shaft- to-steering gear
is binding or
misaligned. z
REPAIR or INSTALL a
new
intermediate/flexible
shaft as necessary.
REFER to Section 211 -
04 .
z Grounded or loose
steering column boot at
the dash panel. z
REPAIR as necessary.
z Damaged or worn
steering gear input
shaft and valve. z
REPAIR or INSTALL a
new steering gear as
necessary. REFER to
Section 211 - 02 .
z Steering column
rattle z
Loose bolts or
attaching brackets. z
TIGHTEN the bolts to
specifications.
z Loose, worn or
insufficiently lubricated
column bearings. z
LUBRICATE or
INSTALL new steering
column bearings as
necessary. REFER to
Section 211 - 04 .
z Steering shaft
insulators damaged or
worn. z
INSTALL new
insulators. REFER to
Section 211 - 04 .
z Intermediate/flexible
shaft compressed or
extended. z
INSPECT the rubber
spider coupling for
damage. INSTALL a
new
intermediate/flexible
shaft. REFER to Section 211 - 04 .
z Steering column
squeak or cracks z
Insufficient lubricated
steering shaft
bushings. z
LUBRICATE the
steering shaft and shaft
tube seals.
z Loose or misaligned
steering column
shrouds. z
TIGHTEN or ALIGN the
steering column
shrouds.
z Steering wheel rubbing
against steering
column shrouds. z
REPOSITION the
steering column
shrouds.
z Insufficient lubricated
speed control slip ring. z
LUBRICATE the speed
control slip ring.
z Upper or lower bearing
sleeve out of position. z
REPOSITION the
bearing sleeves.
z Power steering
pump noisy z
Incorrect assembly of
components.
z Imperfections on the
outside diameter or z
REPAIR or INSTALL a
new power steering
pump as necessary.
REFER to Section 211 -Klj . 35 ba
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z
Is the ticking noise gone? CHECK for TSB for applicable vehicle.
REPAIR as necessary. TEST the system
for normal operation.
No
GO to
B2 .
B2 CHECK FOR TICKING NOISE AT THE FUEL
INJECTOR z
Using an EngineEAR, listen at the fuel
injectors by placing a probe on each injector.
To isolate the faulty injector, disconnect the
injector electrical connector and listen for the
noise.
z Is the fuel injector the source of the ticking
noise? Yes
INSTALL a new fuel injector. REFER to
Section 303
- 04A for 3.8L engines or
Section 303 - 04B for 4.6L (2V) engines.
TEST the system for normal operation.
No
GO to B3 .
B3 CHECK THE BELT TENSIONER FOR TICKING
NOISE z
Inspect the accessory drive. Check for the belt
tensioner bottoming at end of travel or not at
end of stroke.
z Using an EngineEAR, listen at the belt
tensioner.
z Is the belt tensioner the source of the
noise? Yes
INSTALL a new belt tensioner. TEST the
system for normal operation.
No
GO to
B4 .
B4 CHECK THE WATER PUMP FOR TICKING
NOISE z
Using an EngineEAR, listen at the water pump
for ticking noise.
z Is the water pump the source of the noise? Yes
INSTALL a new water pump. REFER to
Section 303
- 03A . TEST the system for
normal operation.
No
GO to B5 .
B5 CHECK FOR AN OBSTRUCTION OF THE
COOLING FAN z
Inspect the cooling fan for obstructions.
z Check the cooling fan and shroud for wear or
damage.
z Was there an obstruction or does the
cooling fan show signs of damage? Yes
REPAIR or INSTALL a new cooling fan.
REFER to
Section 303 - 03A . TEST the
system for normal operation.
No
GO to B6 .
B6 CHECK THE OIL PUMP FOR TICKING NOISE
z
Check the oil pump using EngineEARs and
probe at the oil filter adapter to verify the oil
pump as a source.
z Is the oil pump the source of the noise? Yes
INSTALL a new oil pump. REFER to
Section 303
- 01A for 3.8L engines or
Section 303 - 01B for 4.6L (2V) engines.
TEST the system for normal operation.
No
GO to B7 .
B7 CHECK VALVE LIFTERS OR LASH
ADJUSTERS FOR CORRECT OPERATION z
Check valve lifter/lash adjuster for correct
operation, using EngineEARs.
z Are the valve lifters/lash adjusters Yes
VERIFY customer concern. CONDUCT a
diagnosis of other suspect components. Klj . 50 ba
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PINPOINT TEST L: CLUTCH VIBRATION appropriate workshop manual for the service procedures.
z Secure the brake drums (if so equipped), by installing wheel
hub bolt nuts, reversed.
z Carefully accelerate the drivetrain while checking for vibration.
z Is the vibration present? assemblies as necessary.
TEST the system for
normal operation.
Test Step Result / Action to Take
L1 CHECK ENGINE COMPONENTS FOR GROUNDING
z
NOTE: Make sure the clutch is the cause of the
vibration concern. The vibration should occur during
clutch operation. The clutch can also be difficult to
engage or disengage. Eliminate all related systems
before checking the clutch components.
z NOTE: Check the driveline angles and driveshaft
runout before disassembling the clutch system. Refer
to Section 205 - 00 for the correct driveline angle
specifications.
z Check the powertrain/drivetrain mounts, exhaust
manifolds or other engine components for grounding
on the chassis.
z Are any mounts or engine components
grounded? Yes
REPAIR as necessary. TEST the
system for normal operation.
No
GO to
L2 .
L2 CHECK THE ACCESSORY DRIVE
z
Remove the accessory drive belt.
z Does the vibration stop with the accessory drive
belt removed? Yes
DIAGNOSE the accessory drive
components.
No
GO to
L3 .
L3 CHECK FOR LOOSE CLUTCH PRESSURE PLATE
BOLTS z
Check for loose clutch pressure plate bolts. Inspect
the clutch pressure plate for damage or for material
between the pressure plate and flywheel.
z Are there any loose bolts or damage? Yes
TIGHTEN the bolts to
specifications or if damaged,
INSTALL a new clutch pressure
plate. REFER to
Section 308 - 01 .
TEST the system for normal
operation.
No
GO to L4 .
L4 CHECK THE CLUTCH DISC SPRINGS
z
Check for worn, broken or loose clutch disc springs.
z Are the clutch springs worn, broken or loose? Yes
INSTALL a new clutch disc.
REFER to
Section 308 - 01 . TEST
the system for normal operation.
No
GO to L5 .
L5 CHECK THE CLUTCH DISC SPLINES
z
Inspect the clutch disc splines for damage or wear.
z Is there damage or wear? Yes
INSTALL a new clutch disc.
REFER to
Section 308 - 01 . TEST Klj . 61 ba
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DESCRIPTION AND OPERATION
Wheels And Tires
WARNING: Do not mix different types of tires, such as radial, bias, or bias- belted, on the
same vehicle except in emergencies. Vehicle handling can be seriously affected and can result
in loss of control.
Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including
full- rated load capacity when inflated to recommended inflation pressures.
Tire and Wheel Runout
Excessive radial and lateral runout of a wheel and tire assembly can cause roughness, vibration,
wheel tramp, tire wear, and steering wheel tremor.
Before checking runout, and to avoid false readings caused by temporary flat spots in the tires, check
runout only after the vehicle has been driven far enough to warm the tires. For additional information,
refer to Section 100 - 04 .
SECTION 204-
04: Wheels and Tires 2003 Mustang Workshop Manual Klj . 1 ba
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PINPOINT TEST D: EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL
PINPOINT TEST E: HYDRO-
BOOST, NO POWER ASSIST 4481 kPa (510-
650 psi)? INSTALL a new proportioning valve.
RETEST for normal operation.
Test Step Result / Action to Take
D1 CHECK FOR SPONGY PEDAL
z
Key in ON position.
z Operate the brake pedal and note pedal feel.
z Does the pedal feel spongy? Yes
BLEED the brake system. REFER to
Bleeding —
System in this section.
RETEST for normal operation.
No
GO to D2 .
D2 CHECK THE BRAKE PEDAL
z
Inspect the brake pedal and bracket for
binding, obstruction or damage.
z Is the brake pedal OK? Yes
GO to
D3 .
No
REPAIR or INSTALL a new brake pedal as
necessary. RETEST for normal operation. D3 CHECK THE BRAKE COMPONENTS
z
Inspect the calipers bolts, anchor plate bolts
and anti- rattle springs for binding, damage,
contamination and correct installation.
z Are the bolts and springs OK? Yes
GO to
D4 .
No
REPAIR or INSTALL new components as
necessary. RETEST for normal operation. D4 CHECK THE BOOSTER AND MASTER
CYLINDER z
Check the power brake booster and brake
master cylinder for correct installation and
correct push rod adjustment. Refer to
Section 206 - 06 and to Section 206 - 07 .
z Are the power brake booster and the
brake master cylinder OK? Yes
INSPECT the front wheel bearings for
wear, damage and correct installation and
the rear axle end play. CORRECT as
necessary. RETEST for normal operation.
No
CORRECT as necessary. RETEST for
normal operation.
Test Step Result / Action to Take
E1 CHECK FLUID LEVEL IN POWER STEERING
PUMP z
Check fluid level in power steering pump.
z Is level within specification? Yes
GO to
E2 .
No
CHECK for leakage of power steering
fluid. ADD fluid as necessary. E2 CHECK ACCESSORY DRIVE BELT Klj . 10 ba
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PINPOINT TEST F: HYDRO-
BOOST ERRATIC OPERATION, STICKS,
BINDS OR GRABS z
Check accessory drive belt tension and
condition. Refer to Section 303 - 05 .
z Is the accessory drive belt OK? Yes
GO to
E3 .
No
INSTALL a new accessory drive belt.
REFER to Section 303 - 05 .
E3 CHECK POWER STEERING HOSES
z
Check power steering pressure hoses, power
steering gear pressure hoses and power
steering return hose for cracks or leaks.
z Do power steering pressure hose, power
steering gear hose and power steering
return hose check OK? Yes
GO to
E4 .
No
INSTALL new hoses as necessary.
REFER to Section 211 - 00 .
E4 CHECK BRAKE PEDAL LINKAGE
z
Check brake pedal linkage for binding or
sticking operation.
z Does pedal linkage check OK? Yes
GO to
E5 .
No
INSTALL new pedal linkage as necessary.
REFER to Section 206 - 06 .
E5 CHECK POWER STEERING PUMP SPEED
z
Check engine idle speed against
specifications.
z Is engine idle speed OK? Yes
GO to
E6 .
No
SET engine idle speed to specification.
REFER to Powertrain Control/Emissions
Diagnosis (PC/ED) manual. E6 CHECK FOR PLUGGED RETURN HOSE
z
NOTE: The return hose from the oil cooler to
the power steering reservoir has an in- line
filter in the hose.
z Disconnect power steering return hose from
power steering fluid cooler and power
steering pump reservoir.
z Pass air through hose from the oil cooler end.
z Is hose plugged? Yes
INSTALL a new power steering return
hose.
No
GO to
E7 .
E7 CHECK POWER STEERING PUMP FLOW
AND RELIEF z
Test power steering pump for correct flow
and relief pressure. Refer to Section 211 - 00 .
z Is power steering pump operating
correctly? Yes
INSTALL a new power brake hydro-
boost
unit. REFER to Section 206 - 07 .
No
INSTALL a new power steering pump.
REFER to Section 211 - 02 .
Test Step Result / Action to
Take F1 CHECK SUPPLY HOSE
z
Check for obstructions in power steering return hose and Yes Klj . 11 ba
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1. Verify the customer concern by operating the steering system.
2. Inspect Tires
zCheck the tire pressure. Refer to the Vehicle Certification (VC) label.
z Verify that all tires are sized to specification.
z Check the tires for damage or uneven wear.
3. Belt and Tensioner Check zRefer to Section 303 - 05 for diagnosis and testing of the accessory drive system.
4. Fluid Level Check zVerify that the power steering fluid level is within the appropriate indicated range, hot for
the 3.8L engine and cold for the 4.6L engine. Add Motorcraft MERCON® Multi- Purpose
ATF XT -2-QDX or MERCON® equivalent.
5. Air Bleeding zVerify that there is no air in the power steering system. Run the engine (6007) until it
reaches normal operating temperature. Turn the steering wheel to the left and right
several times without hitting the stops. If any air bubbles are present, refer to Purging —
CII Power Steering Pump or
Purging — CIII Power Steering Pump in this section.
External Leak Check — Typical Power Rack-and-Pinion Steering Gear Klj . 2 ba
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Component Tests
Steering Linkage
1. NOTE: Excessive vertical motion of the studs relative to the sockets may indicate excessive
wear.
With the parking brake applied, perform the following:
zHave an assistant rotate the steering wheel back and forth 360 degrees and watch for
relative motion of the studs in the tie- rod end ball sockets.
z Watch for loose steering gear mounting.
2. Another method is to raise the front wheels (1007) off the ground, grasp the wheel at the front and rear and watch for excessive play or binding in the joints while trying to steer the wheels.
3. Install new steering components as necessary. For additional information, refer to the appropriate Group 2 steering section.
Turning Effort Test
NOTE: Make sure that the front wheels are properly aligned and the tire pressure is correct before
checking the effort.
1. Park the vehicle on dry concrete and set the parking brake.
2. Insert a thermometer into the power steering pump reservoir.
3. CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump will occur.
Idle the engine for two to three minutes. Turn the steering wheel from stop- to-stop several times
to warm the fluid to 50- 60°C (122-140°F).
4. With the engine running, attach special tool 211- 034 (T74P-3504-Y) to the rim of the steering
wheel.
5. Measure the pull required to turn the steering wheel one complete revolution in each direction. Refer to Steering Wheel Turning Effort under General Specifications in this section.
Pump Flow and Pressure Test WARNING: Do not touch the flowmeter during the test procedure, or severe burns and
serious injury may occur.
1. CAUTION: Make sure that the connection point will not interfere with any of the
engine accessory drive components or drive belts.
Install special tool 211- F001 (014-00207) at the high pressure port of the power steering pump.
Make sure the power steering analyzer gate valve is fully open. Klj . 8 ba
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