2003 FORD MUSTANG overheating

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Torque Converter
1. A new or remanufactured torque converter must be installed if one or more of the following statements is true:
zA torque converter malfunction has been determined based on complete diagnostic
procedures.
z Converter stud or studs, impeller hub or bushing are damaged.
z Discoloration (due to overheating).
z The torque converter is found to be out of specification when carrying out one of the
following torque converter checks:
„One- Way Clutch Check
„ End Play Check
„ Stator to Turbine Interference Check
„ Stator to Impeller Interference Check
„ Torque Converter Leak Check
z Evidence of transmission assembly or fluid contamination due to the following
transmission or converter failure modes:
„Major metallic failure.
„ Multiple clutches or clutch plate failures.
„ Sufficient component wear which results in metallic contamination.
SECTION 307-
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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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REMOVAL AND INSTALLATION
Flywheel Ring Gear
Removal
1. Remove the flywheel. For additional information, refer to Section 303 - 01A ,
Section 303 - 01B or
Section 303 - 01C .
2. WARNING: This procedure should be carried out only by a correctly equipped and
experienced acetylene torch operator. Tongs must be used or asbestos gloves worn
when handling the heated flywheel ring gear. Failure to follow these instructions can
result in personal injury.
CAUTION: Tap the flywheel ring gear evenly to prevent binding.
Remove the flywheel ring gear from the flywheel. zEvenly heat the flywheel ring gear with an acetylene torch and use a brass drift to drive
the flywheel ring gear off the flywheel.
Installation
1. WARNING: This procedure should be carried out only by a properly equipped and
experienced acetylene torch operator. Tongs must be used or asbestos gloves worn
when handling the heated flywheel ring gear. Failure to follow these instructions can
result in personal injury.
CAUTION: Do not heat the flywheel ring gear beyond 261°C (500°F). Use heat-
indicating crayons to prevent overheating.
CAUTION: Keep the torch moving to prevent hot spots.
Evenly heat the flywheel ring gear with an acetylene torch. zInstall the flywheel ring gear with the bevel on the flywheel ring gear facing the rear of the
flywheel.
z Use a brass drift to tap the flywheel ring gear into position, reheat as necessary.
2. Install the flywheel. For additional information, refer to Section 303 - 01A ,
Section 303 - 01B or
Section 303 - 01C . SECTION 308-
01: Clutch 2003 Mustang Workshop Manual Klj . 1 ba
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GENERAL PROCEDURES
Bearings —
Inspection
NOTE: If any of the following conditions exist, install a new bearing.
1. Inspect the bearing for a bent cage.
2. Inspect bearings for galling (metal smears on roller ends). zGalling is caused by overheating, poor lubrication or an overload situation.
z If galling is found, install a new bearing and inspect the seals.
3. Inspect the bearing for brinelling (surface indentations in the raceway).
4. Inspect bearing for cracked inner race.
SECTION 308-
03B: Manual Transaxle/Transmission — TR3650 2003 Mustang Workshop Manual Klj . 1 ba
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COOL (blue) to WARM (red) causes a corresponding movement on the air temperature control
door and determines the temperature that the system will maintain.
z The A/C heater function selector switch combines a vacuum selector valve for direct control of
the vacuum control motors and electrical input to the instrument control module.
Control System Outputs
Blower Motor Switch Resistor
The heater blower motor switch resistor has the following features:
zThe assembly is located on the passenger side of the plenum assembly behind the glove
compartment (06010).
z Three resistance elements are mounted on the resistor board to provide four A/C blower motor
speeds.
z Depending on the heater blower motor switch position, series resistance is added or bypassed
in the A/C blower motor circuit to decrease or increase A/C blower motor speed.
z An overheating protective device (thermal limiter) will open the resistor coil circuit when the
temperature reaches 105°- 110°C (221°-230°F), interrupting the blower motor operation in all
speeds except HI.
z The thermal limiter cannot be reset and is not serviceable.
Control Actuators
Temperature Control Cable
The temperature control cable (19988) has the following features:
zThe cable assembly has a constant tension (pull- pull) dual cable design.
z The pull- pull design allows for constant smooth communication between the temperature control
knob and the air temperature blend door.
z The control cable can only be installed as an assembly.
Vacuum Control Motors
The vacuum control motors (18A318) control the position of the doors directing the air flow to the
different outlets. There are two types of vacuum control motors used in this system:
zSingle- diaphragm for air inlet and windshield defroster door operations.
z Double- diaphragm for air damper door operations.
Single- diaphragm motors have two positions:
z Shaft extended with no vacuum applied.
z Shaft retracted with vacuum applied.
Double- diaphragm motors have three positions:
z Shaft extended with no vacuum applied to either port.
z Shaft halfway retracted with vacuum applied to only one port. Klj . 3 ba
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Tin the bus bar repair area with solder.
4. CAUTION: To prevent overheating the rear window glass, remove the soldering gun
as soon as the solder flows.
Preheat the rear window glass in the area to be repaired using the special tool and solder the
terminal to the bus bar.
5. NOTE: Turn the heated rear window switch ON for five minutes prior to the final inspection of
the repair.
Apply rear window defroster repair to the area as needed. Klj . 2 ba
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