2003 FORD MUSTANG stop start

60.
NOTE: Use reference marks made during removal to aid in the installation.
Install the hood and the four nuts.
61. Install the hood- to-body ground strap.
62. Connect the battery ground cable. For additional information, refer to Section 414 - 01 .
63. Fill the crankcase with clean engine oil and check that all other fluids are at the correct levels.
64. Fill and bleed the engine cooling system. For additional information, refer to Section 303 - 03A .
65. Fill and purge the power steering system. For additional information, refer to Section 211 - 00 .
66. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
67. Charge the A/C system. For additional information, refer to Section 412 - 00 . Klj . 16 ba
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65. Install the hood-
to-body ground strap.
66. Connect the fuel spring lock coupling. For additional information, refer to Section 310 - 00 .
67. Install the air intake scoop bracket. For additional information, refer to Section 303 - 12 .
68. Connect the battery ground cable. For additional information, refer to Section 414 - 01 .
69. Fill the crankcase with clean engine oil and check that all other fluids are at the correct levels.
70. Fill and bleed the engine cooling system. For additional information, refer to Section 303 - 03A .
71. Fill and purge the power steering system. For additional information, refer to Section 211 - 00 .
72. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
73. Charge the A/C system. For additional information, refer to Section 412 - 00 . Klj . 18 ba
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SPECIFICATIONS
SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual General Specifications
Item Specification
Cooling System Capacity 15.2 L (4.0 gal)
Coolant Type
Motorcraft Premium Gold Engine Coolant VC-7-
A in
(Oregon VC -7-B) (yellow color) WSS-
M97B51- A1 Other Chemicals
Motorcraft Premium Cooling System Flush VC-
1 ESR-
M14P7-A Premium Long Life Grease XG-1-
C ESA-
M1C75- B Cooling System Stop Leak Pellets
VC-
6 ESE-
M99B37- B5 except as noted in ES-
F65E-19A511- AA Gasket Adhesive TA-
6 WSS-
M2G408- A Cooling System Pressure Test Specifications 138 kPa (20 psi)
Radiator Cap Pressure Test Specifications 110 kPa (16 psi)
Thermostat Opening Temperatures
Starts to open (4.6L 2V) 87-
93°C (192- 199°F) Starts to open (3.8L) 86.7-
90.6°C (189- 196°F) Starts to open (Cobra) 80-
83°C (175- 182°F) Fully open 104°C (219°F)
Torque Specifications Description Nm lb-
ft lb-
in Accelerator cable bracket bolts 10 — 89
Cylinder block drain plug 20 15 —
Exhaust manifold to EGR valve tube nut 35 26 —
Fan shroud bolts 10 — 89
Fan motor bolts 10 — 89
Degas bottle nuts 10 — 89
Coolant expansion tank bracket bolts 10 — 89
Radiator support bracket bolts 30 22 —
Transmission fluid cooler fittings 30 22 —
Coolant outlet connection bolts (3.8L) 10 — 89
Bypass tube bracket bolts (3.8L) 10 — 89
Bypass tube bolts (4.6L) 10 — 89
Bypass tube nuts (Supercharged engine) 25 18 —
Coolant hose mounting bolt 25 18 — Klj . 1 ba
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14. Install the air intake scoop. For additional information, refer to
Section 303 - 12 .
Bleeding 1. Select the maximum heater temperature and blower motor speed settings. Position the control to discharge air at A/C vents in instrument panel.
2. Start the engine and allow to idle. While engine is idling, feel for hot air at A/C vents.
3. CAUTION: If the air discharge remains cool and the engine coolant temperature
gauge does not move, the engine coolant level is low and must be filled. Stop the engine,
allow the engine to cool and fill cooling system.
Start the engine and allow it to idle until normal operating temperature is reached. Hot air should
discharge from A/C vents. The engine coolant temperature gauge should maintain a stabilized
reading in the middle of the NORMAL range. The upper radiator hose should feel hot to the
touch.
4. Shut the engine off and allow the engine to cool.
5. Check the engine for coolant leaks.
6. Check the engine coolant level in the degas bottle/coolant expansion tank and fill as necessary. Klj . 7 ba
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Component Tests
Drive Belt Noise/Flutter
Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a
damaged pulley or an incorrectly aligned pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area
with a straightedge to the crankshaft pulley, looking for accessory pulleys out of position in the fore/aft
direction or at an angle to the straightedge.
Drive belt squeal is an intermittent noise that occurs when the drive belt slips on a pulley during certain
conditions, such as: engine start up, rapid engine acceleration, or A/C clutch engagement.
Drive belt squeal can occur:
zif any of the accessories are damaged, have a worn or damaged bearing, internal torsional
resistance above normal. All accessories should be rotatable by hand in the unloaded condition.
If not, inspect the accessory.
z if fluid gets on the drive belt. This includes power steering fluid, engine coolant, engine oil or air
conditioning system lubricant. If fluid does get on the drive belt during service, clean the drive
belt with soap and water and thoroughly rinse with clean water.
z NOTE: The drive belt tensioner arm should rotate freely without binding.
if the drive belt is too long. A drive belt that is too long will allow the drive belt tensioner arm to
go all the way to the arm travel stop under certain load conditions, which will release tension to
the drive belt. If the drive belt tensioner indicator is outside the installation wear range window,
install a new drive belt.
z if the drive belt tensioner is worn or damaged.
Belt Tension
NOTE: Drive belt tension is not adjustable.
The drive belt tensioner automatically adjusts drive belt tension. Symptom Chart Condition
Possible Sources Action
z Drive belt
noise, chirping,
flutter z
Defective/worn drive
belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Fluid contamination
of drive belt. z
GO to Component Tests, Drive
Belt, Noise/Flutter.
z Damaged or worn
drive belt tensioner. z
GO to Component Tests, Belt
Tensioner, Automatic.
z Premature
drive belt wear z
Defective drive belt.
z Misaligned pulley.
z Pulley runout.
z Damaged
accessories.
z Incorrectly installed
drive belt. z
GO to Component Tests, Drive
Belt Noise/Flutter and Drive
Belt Misalignment diagnosis. Klj . 2 ba
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C1 VERIFY DIAGNOSTIC TROUBLE CODES
z
Select PARK.
z Key in OFF position.
z NOTE: DTC codes P0705 and P0708 cannot be set by
an incorrectly adjusted digital TR sensor.
z Carry out on board diagnostic test.
z Are only DTC codes P0705, P0708 present? Yes
GO to
C4 .
No
GO to C2 .
C2 VERIFY DIGITAL TRANSMISSION RANGE SENSOR
ALIGNMENT z
Check to make sure the digital TR sensor harness
connector is fully seated, pins are fully engaged in
connector and in good condition before proceeding.
z Apply the parking brake.
z Select NEUTRAL.
z Disconnect the shift cable/linkage from the manual lever.
z Verify that the digital TR Sensor Alignment Tool fits in
the appropriate slots.
z Is the digital TR sensor adjustment OK? Yes
GO to
C3 .
No
ADJUST the digital TR sensor.
PLACE transmission range
selector lever in P and CLEAR
DTCs. REPEAT OBD Tests.GO
to C3 .
C3 VERIFY SHIFT CABLE/LINKAGE ADJUSTMENT
z
Place the manual lever in the overdrive position.
z Select DRIVE.
z Reconnect the shift cable/linkage.
z Verify that the shift cable/linkage is adjusted OK. Refer
to Section 307 - 05 .
z Is the shift cable/linkage adjusted OK? Yes
GO to
C4 .
No
ADJUST the shift cable/linkage.
REFER to Section 307 - 05 .
C4 CHECK ELECTRICAL SIGNAL OPERATION
z
Select PARK.
z Disconnect: Digital TR Sensor.
z CAUTION: Do not pry on connector. This will
damage the connector and result in a transmission
concern.
z Press the button and pull out on the digital TR harness
connector.
z Inspect both ends of the connector for damage or
pushed- out pins, corrosion, loose wires and missing or
damaged seals.
z Are the connector, pins and harness damaged? Yes
REPAIR as required. CLEAR
DTCs and REPEAT OBD
Tests.
No
If diagnosing a DTC, GO to
C5
.
If diagnosing a starting concern
or a reversing lamp concern,
GO to C10 .
C5 CHECK ELECTRICAL SYSTEM OPERATION (DIGITAL
TR AND PCM) z
Key in OFF position.
z Connect the diagnostic tool.
z Connect: Digital TR Sensor.
z Key in ON position.
z Enter the following diagnostic mode on the diagnostic
tool: TR PIDS TR, TR_D, TR_V.
z Move transmission range selector lever into each gear
and stop.
z Observe any of the following PIDs, TR and TR_D, TR_V
(vehicle dependent) while wiggling harness, tapping on
sensor, or driving the vehicle. Use PIDs TR, and TR_D
for DTCs P0705, P1704, and P1705. Use PIDs TR, and
TR_V for DTC P0708.
z Compare the PIDs to the Digital Transmission Range
(TR) Sensor Diagnosis Chart.
z Do the PIDs TR, TR_D and TR_V match the Digital
Transmission Range (TR) Sensor Diagnosis chart,
and does the TR_D PID remain steady when the Yes
The problem is not in the digital
TR sensor system. REFER to
Diagnosis By Symptom
in this
section for further diagnosis.
No
If TR_D changes when wiggling
harness, tapping on the sensor,
or driving the vehicle, the
problem may be intermittent.
GO to C6 . Klj . 10 ba
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DIAGNOSIS AND TESTING
Transmission Fluid Cooler
CAUTION: Whenever a transmission has been disassembled to install new parts, the
cooler bypass valve (CBV), all transmission fluid coolers (in tank and auxiliary) and
transmission fluid cooler lines must be cleaned and backflushed. Use a suitable the torque
converter/fluid cooler cleaner.
NOTE: Cleaning and backflushing the transmission fluid cooling system along with following all the
normal cleaning and inspection procedures in this section during disassembly and reassembly will
keep contamination from reentering the transmission and causing a repeat repair.
When internal wear or damage has occurred in the transmission, metal particles, clutch plate material,
or band material may have been carried into the torque converter and transmission fluid cooler. These
contaminants are a major cause of recurring transmission troubles and must be removed from the
system before the transmission is put back into use.
Transmission Fluid Cooler Flow Test
NOTE: The transmission linkage/cable adjustment, fluid level and line pressure must be within
specification before carrying out this test. Refer to Section 307 - 05 for adjustments.
1. Remove fluid level indicator from fluid filler tube.
2. Place funnel in fluid filler tube.
3. Position the vehicle on a hoist. For additional information, refer to Section 100 - 02 .
4. Remove the cooler return line (top fitting) from the fitting on the transmission case.
5. Connect one end of a hose to the cooler return line and route other end of the hose up to a point where it can be inserted into the funnel at the fluid filler tube.
6. Remove the safety stands and lower the vehicle. Insert end of hose into the funnel.
7. Start the engine and run it at idle with the transmission in NEUTRAL.
8. When fluid flows from the hose in a steady stream, a liberal amount of fluid should be observed. "Liberal" is about 1 liter (1 quart) delivered in 15 seconds. If a liberal flow is observed, the test is
complete.
9. If the flow is not liberal, stop the engine. Disconnect the hose from the cooler return line and connect it to the converter outlet fitting (bottom fitting) on the transmission case.
10. Repeat steps 6 and 7. If flow is now approximately 1 liter (1 quart) in 15 seconds, refer to Transmission Fluid Cooler — Backflushing and Cleaning in this section. If the flow is still not
approximately 1 liter (1 quart) in 15 seconds, repair or install pump and or converter.
For the installation of new transmission fluid cooler or tubes, refer to Section 307 - 02 .
SECTION 307-
01: Automatic Transaxle/Transmission 2003 Mustang Workshop Manual Klj . 1 ba
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PINPOINT TEST D: CLUTCH PEDAL PULSATION clutch disengaged and engine idling, move
the shift lever to a position halfway between
REVERSE and NEUTRAL.
z Slowly engage clutch. The transmission will
behave as if it is in NEUTRAL.
z Gear clash can now be heard if an attempt
is made to shift into REVERSE with the
clutch engaged. Reserve can now be
measured.
z While maintaining light pressure on the shift
selector, slowly press the clutch pedal to the
floor. The gear clash will stop and the shift
selector will slide into the REVERSE
position.
z Is there a minimum 19.05 mm (0.750 inch)
clutch pedal reserve? CHECK the clutch pressure plate and clutch
disc. INSTALL a new clutch pressure plate
or clutch disc if necessary. REFER to
Section 308
- 01 . TEST the system for
normal operation. Test Step Result / Action to Take
D1 CHECK THE CLUTCH PEDAL
PULSATION z
Key in START position.
z With the transmission in NEUTRAL,
slowly press the clutch pedal.
z Does the clutch pedal pulsate while
being pressed? Yes
GO to
D2 .
No
VERIFY customer concern. GO to Symptom Chart if necessary.
D2 INSPECT PRESSURE PLATE BOLTS
z
Inspect the pressure plate- to-flywheel
bolts.
z Are any of the pressure plate- to-
flywheel bolts loose? Yes
TIGHTEN or INSTALL new bolts. REFER to
Section 308
- 01 . TEST the system for normal
operation.
No
GO to D3 .
D3 INSPECT THE CLUTCH PRESSURE
PLATE z
Remove the clutch pressure plate.
Refer to Section 308 - 01 .
z INSPECT the clutch pressure plate for
damage. Refer to Pressure Plate Check .
z Are there any signs of damage
present on the clutch pressure plate? Yes
INSTALL a new clutch pressure plate. REFER
to
Section 308 - 01 . TEST the system for normal
operation.
No
GO to D4 .
D4 INSPECT THE CLUTCH DISC
z
Carry out the clutch disc inspection
procedure. Refer to Disc Check .
z Is the clutch disc OK? Yes
GO to
D5 .
No
INSTALL a new clutch disc. REFER to Section 308 - 01 . TEST the system for normal operation.
D5 INSPECT THE FLYWHEEL Klj . 9 ba
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