2003 FORD MUSTANG suspension

„
A wobble or shudder. GO to Symptom Chart — Tire Noise/Vibration .
2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart — Suspension
Noise/Vibration .
„ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart — Squeak and Rattle .
„ Noise or vibration changes from one road surface to another. Normal sound
changes.
„ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart —
Suspension Noise/Vibration .
Symptom Charts Symptom Chart — Air Leak and Wind Noise Condition
Possible Sources Action
z Air leak around
door perimeter z
Loose fit seal. zPINCH the seal carrier to
improve retention on the
seal flange.
z Seal installed
incorrectly. z
REINSTALL the seal.
z Door misaligned. zREALIGN the door.
CHECK door gaps and fit
in the door opening and
ADJUST as necessary.
z Scuff plate installed
incorrectly. z
REINSTALL the scuff
plate.
z Seal or seal push pins
damaged. z
INSTALL a new seal.
z Air leak around
glass run z
Door glass misaligned. zADJUST the door glass.
z Glass run installed
incorrectly. z
ADJUST the glass run.
INSERT foam in the glass
run carrier.
z Leak path behind glass
run. z
INSTALL foam rope
behind the glass run.
z Glass run channel
spread wide. z
PINCH the glass run
channel to reduce the size
of the opening.
z Blow- out clip bent or
contacting door glass. z
ADJUST the blow- out clip
or INSTALL a new glass
run/blow- out clip molding
assembly.
z Glass run damaged. zINSTALL a new glass run.
z Air leak at inner
belt line z
Belt line seal installed
incorrectly on flange. z
ADJUST the seal. (Do not
bend the flange.)
z Belt line seal integrated
with door trim installed
incorrectly (no glass
contact). z
REINSTALL the door trim. Klj . 12 ba
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occurs on first
(morning) brake
application
pads.
Caused by humidity and
low disc brake pad
temperature.
z Squealing noise— a
continuous squeal z
Disc brake pads
or linings worn
below minimum
thickness. z
INSTALL new disc brake
pads. REFER to Section 206 - 03 for front disc brake
pads or Section 206 - 04 for
rear disc brake pads.
z Squealing noise— an
intermittent squeal
brought on by cold,
heat, water, mud or
snow z
Disc brake pad. zAcceptable condition.
z Groaning noise—
occurs at low speeds
with brake lightly
applied (creeping) z
Disc brake
pads. z
Acceptable condition.
z Grinding noise—
continuous z
Disc brake pads
or linings worn
below minimum
thickness. z
INSPECT the disc brake
pads, brake discs and
attaching hardware for
damage. REPAIR or
INSTALL new components
as necessary. REFER to
Section 206 - 03 for front
disc brakes and Section 206 - 04 for rear disc brakes.
z Moaning noise zBrake linings
contaminated
with grease or
oil. z
INSPECT the brake pads
and shoes for
contamination. REPAIR or
INSTALL new components
as necessary. REFER to
Section 206 - 03 for front
disc brakes or Section 206 -
04 for rear disc brakes.
z Brake
vibration/shudder—
occurs when brakes
are applied z
Uneven disc or
drum wear.
z Uneven disc
brake pad or
lining transfer.
z Suspension
components. z
Go To Pinpoint Test A .
z Brake
vibration/shudder—
occurs when the brake
pedal is released z
Brake drag. zINSPECT the disc brake
pads or linings for
premature wear. REPAIR
or INSTALL a new caliper
or wheel cylinder as
necessary. REFER to
Section 206 - 03 for front
disc brakes and Section 206 - 04 for rear disc brakes.
Symptom Chart—
Driveline Noise/Vibration Condition
Possible Sources Action
z Axle howling or
whine— front or rear
axle z
Axle lubricant
low. z
CHECK the lubricant level.
FILL the axle to
specification.
z Axle housing zINSPECT the axle housing Klj . 17 ba
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damage.
for damage. REPAIR or
INSTALL a new axle as
necessary. REFER to
Section 205 - 02A for Ford
7.5 rear axles or Section 205 - 02B for Ford 8.8
integral axles.
z Damaged or
worn wheel
bearings or axle
bearings. z
CHECK for abnormal wheel
bearing play or roughness.
REFER to Wheel Bearing Check in this section.
ADJUST or INSTALL new
wheel bearings as
necessary.
z Damaged or
worn differential
ring and pinion. z
INSPECT the ring and
pinion ring for abnormal
wear patterns or broken
teeth. INSTALL a new ring
and pinion as necessary.
REFER to Section 205 - 02A
for Ford 7.5 rear axles or
Section 205
- 02B for Ford
8.8 integral axles.
z Damaged or
worn differential
side or pinion
bearings. z
CHECK for abnormal
bearing play or roughness.
INSTALL new bearings as
necessary.
z Damaged or
worn differential
side gears and
pinion gears. z
DISASSEMBLE the
differential carrier. INSPECT
the side and pinion gears for
abnormal wear patterns or
broken teeth. INSTALL new
gears as necessary. REFER
to Section 205 - 02A for Ford
7.5 rear axles or Section 205 - 02B for Ford 8.8
integral axles.
z Driveline clunk— loud
clunk when shifting
from reverse to drive z
Incorrect axle
lubricant level. z
CHECK the lubricant level.
FILL the axle to
specification.
z Excessive
backlash in the
axle or
transmission. z
CARRY OUT a total
backlash check. REFER to
Section 205 - 00 .
z Damaged or
worn pinion
bearings. z
CHECK for abnormal
bearing play or roughness.
INSTALL new bearings as
necessary. REFER to
Section 205 - 02A for Ford
7.5 rear axles or Section 205 - 02B for Ford 8.8
integral axles.
z Damaged or
worn universal
joints (U- joints). z
INSPECT the U- joints for
wear or damage. INSTALL
new U- joints as necessary.
REFER to Section 205 - 01 .
z Loose
suspension
components. z
INSPECT the suspension
for damage or wear.
REPAIR or INSTALL new Klj . 18 ba
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components as necessary.
z Broken
powertrain
mounts. z
INSPECT the powertrain
mounts. INSTALL new
mounts as necessary.
REFER to Section 303 - 01A
for 3.8L engines or
Section 303 - 01B for 4.6L (2V)
engines.
z Idle speed too
high. z
CHECK for the correct idle
speed.
z Driveline clunk—
occurs as the vehicle
starts to move
forward following a
stop z
Worn or galled
driveshaft slip-
yoke splines. z
CLEAN and INSPECT the
splines of the yoke for a
worn or galled condition.
INSTALL a new yoke as
necessary. REFER to
Section 205 - 01 .
z Worn or galled
driveshaft and
coupling shaft
splines. z
CLEAN and INSPECT the
splines of the driveshaft and
coupling shaft for a worn or
galled condition. INSTALL a
new driveshaft assembly as
necessary. REFER to
Section 205 - 01 .
z Loose rear leaf
spring U- bolts. z
CHECK the U- bolts for
loose nuts. TIGHTEN to
specification. REFER to
Section 204 - 02 .
z Driveline clunk (FWD
vehicles)—occurs
during acceleration or
from cruise to
coast/deceleration z
Damaged or
worn inboard
constant velocity
(CV) joint. z
INSPECT the inboard CV
joint and boot. REPAIR or
INSTALL a new CV joint as
necessary.
z Driveline clunk (4WD
vehicles)—occurs
during shift- on-the- fly
engagement z
Clutch relay.
z Shift motor.
z Transfer case.
z GEM. z
CHECK the 4WD
engagement system.
REPAIR or INSTALL new
components as necessary.
z Clicking, popping or
grinding— occurs
while vehicle is
turning z
Inadequate or
contaminated
lubrication in the
(CV) joints. z
CHECK the CV boots and
joints for wear or damage.
REPAIR or INSTALL new
components as necessary.
z Another
component
contacting the
halfshaft. z
CHECK the halfshafts and
the area around the
halfshafts. REPAIR as
necessary.
z Brake
components. z
INSPECT the front brakes
for wear or damage.
REPAIR as necessary.
REFER to Section 206 - 03 .
z Steering
components. z
INSPECT the drag link,
inner and outer tie- rods or
idler arm for wear or
damage. REPAIR as
necessary. REFER to
Section 211 - 02 .
z Suspension
components. z
INSPECT the upper and
lower ball joints for wear or
damage. REPAIR as
necessary. REFER to Klj . 19 ba
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from a dead stop
zLoose rear
spring U- bolts. z
INSPECT the rear
suspension. TIGHTEN the
U-bolt nuts to specification.
REFER to Section 204 - 02 .
z Howl— can occur at
various speeds and
driving conditions.
Affected by
acceleration and
deceleration z
Incorrect ring
and pinion
contact,
incorrect
bearing preload
or gear damage. z
CHECK the ring and pinion
and bearings for damage.
INSPECT the ring and
pinion wear pattern. REFER
to Checking Tooth Contact
Pattern and Condition of the
Ring and Pinion component
test in this section. ADJUST
or INSTALL new
components as necessary.
REFER to Section 205 - 02A
for Ford 7.5 rear axles or
Section 205
- 02B for Ford
8.8 integral axles.
z Chuckle— heard at
coast/deceleration.
Also described as a
knock z
Incorrect ring
and pinion
contact or by
damaged teeth
on the coast
side of the ring
and pinion. z
CHECK the ring and pinion
for damage. INSPECT the
ring and pinion wear pattern.
REFER to Checking Tooth
Contact Pattern and
Condition of the Ring and
Pinion component test in
this section. ADJUST or
INSTALL new components
as necessary. REFER to
Section 205 - 02A for Ford
7.5 rear axles or Section 205 - 02B for Ford 8.8
integral axles.
z Knock— noise occurs
at various speeds.
Not affected by
acceleration or
deceleration z
Gear tooth
damage to the
drive side of the
ring and pinion. z
CHECK the differential case
and ring and pinion for
damage. INSTALL new
components as necessary.
REFER to Section 205 - 02A
for Ford 7.5 rear axles or
Section 205
- 02B for Ford
8.8 integral axles.
z Excessive axle
shaft end play.
(Vehicles with
integral axles). z
CHECK the axle end play
using a dial indicator.
INSTALL a new axle shaft
or side gears as necessary.
REFER to Section 205 - 02A
for Ford 7.5 rear axles or
Section 205
- 02B for Ford
8.8 integral axles.
z Scraping noise— a
continuous low
pitched noise starting
at low speeds z
Worn or
damaged pinion
bearings. z
CHECK the pinion bearings.
INSTALL new pinion
bearings as necessary.
REFER to Section 205 - 02A
for Ford 7.5 rear axles or
Section 205
- 02B for Ford
8.8 integral axles.
z Driveline shudder—
occurs during
acceleration from a
slow speed or stop z
Rear drive axle
assembly
mispositioned. z
CHECK the axle mounts
and the rear suspension for
damage or wear. REPAIR
as necessary. Klj . 21 ba
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z
Loose rear
spring U- bolts. z
INSPECT the U- bolts.
TIGHTEN the U- bolt nuts to
specification. REFER to
Section 204 - 02 .
z Incorrect or high
CV joint
operating angle. z
CHECK vehicle ride height
is within limits. REPAIR as
necessary. REFER to
Section 206 - 00 .
z Damaged or
worn front
suspension
components. z
CHECK for a loose stabilizer
bar, damaged or loose
strut/strut bushings or loose
or worn ball joints. INSPECT
the steering linkage for wear
or damage. REPAIR or
INSTALL new components
as necessary.
z Driveline angles
out of
specification. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to
Section 205 - 00 .
z U-joints binding
or seized. z
ROTATE the driveshaft and
CHECK for rough operation
or seized U- joints. INSTALL
new U- joints as necessary.
REFER to Section 205 - 01 .
z Binding,
damaged or
galled splines
on the driveshaft
slip- yoke z
CLEAN and INSPECT the
splines of the slip- yoke,
driveshaft and coupling
shaft for a worn, damaged
or galled condition.
INSTALL a new slip- yoke or
driveshaft assembly as
necessary. REPAIR as
necessary. REFER to
Section 205 - 01 .
z Driveline vibration—
occurs at cruising
speeds z
U-joints are
worn. z
CHECK for wear or incorrect
seating. INSTALL new U-
joints as necessary. REFER
to Section 205 - 01 .
z Worn or
damaged
driveshaft center
bearing support. z
CHECK the insulator for
damage or wear. ROTATE
the driveshaft and CHECK
for rough operation.
INSTALL a new center
bearing support as
necessary. REFER to
Section 205 - 01 .
z Loose axle
pinion flange
bolts. z
INSPECT the axle pinion
flange. TIGHTEN the pinion
flange bolts to specification.
REFER to Section 205 - 01 .
z Excessive axle
pinion flange
runout. z
CARRY OUT a Runout
Check. REPAIR as
necessary. REFER to
Section 205 - 01 .
z Driveshaft is
out-of- balance. z
CHECK the driveshaft for
damage, missing balance
weights or undercoating.
CHECK driveshaft balance. Klj . 22 ba
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REFILL as necessary.
z Power steering pump
brackets loose or
misaligned. z
CHECK bolts, brackets
and bracket alignment.
TIGHTEN bolts to
specification. REPAIR
or INSTALL new
brackets as necessary.
REFER to Section 211 -
02 .
z Steering gear clunk
— occurs only
while cornering
over a bump (can
be temperature
sensitive) z
Steering gear. zINSPECT the steering
gear for loose mounting
bolts. TIGHTEN as
necessary. REFER to
Section 211 - 02 .
z Feedback (rattle,
chuckle or
knocking noise in
the steering gear)
— a condition
where roughness is
felt in the steering
wheel when the
vehicle is driven
over rough
surfaces z
Column
intermediate/flexible
shaft joints damaged or
worn. z
INSTALL a new
intermediate/flexible
shaft. REFER to Section 211 - 04 .
z Loose, damaged or
worn tie- rod ends. z
TIGHTEN the nuts to
specification or
INSTALL new tie- rod
ends as necessary.
REFER to Section 211 -
02 .
z Steering gear
insulators or mounting
bolts loose or
damaged. z
TIGHTEN the bolts or
INSTALL new bolts as
necessary. REFER to
Section 211 - 02 .
z Steering column
intermediate shaft bolts
are loose. z
TIGHTEN the bolts to
specification. REFER to
Section 211 - 04 .
z Steering column
damaged or worn. z
REPAIR or INSTALL a
new steering column as
necessary. REFER to
Section 211 - 04 .
z Loose suspension
bushings, bolts or ball
joints. z
INSPECT the
suspension system.
TIGHTEN or INSTALL
new components as
necessary. REFER to
Section 204 - 01 .
z Feedback (nibble
at the steering
wheel) — a
condition where
slight rotational
movement is felt in
the steering wheel
when the vehicle is
driven over rough
or grooved z
Lateral runout in the
tire or wheel. z
GO to Pinpoint Test H . Klj . 34 ba
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end surface of the
power steering pump
rotor.
z Damaged or worn
power steering pump
rotor splines.
z A crack on the inner
surface of the power
steering pump cam.
z Interference between
the power steering
pump rotor and cam.
z Damaged or worn
power steering pump
rotor and pressure
plates. 02 .
z Power steering
pump swish noise z
Power steering fluid
flow into the bypass
valve of the pump
valve housing with fluid
temperature below 54°
C (130°F). z
Acceptable condition.
z Power steering
pump whine noise z
Aerated fluid. zPURGE the air from the
system. REFER to
Section 211 - 00 .
CHECK for a leak in the
system.
z Damaged power
steering pump cam. z
REPAIR or INSTALL a
new power steering
pump as necessary.
REFER to Section 211 -
02 .
z Damaged valve cover
O-ring seal. z
REPAIR or INSTALL a
new power steering
pump as necessary.
REFER to Section 211 -
02 .
z Power steering
pump clicking
(mechanical) noise z
Power steering pump
rotor slippers too long,
excessive rotor slipper-
to-slot clearance or
damaged or worn rotor
assembly. z
REPAIR or INSTALL a
new power steering
pump as necessary.
REFER to Section 211 -
02 .
z Power steering
pump clatter noise z
Damaged corners on
the outside diameter or
the power steering
rotor or distorted rotor
slipper ring. z
REPAIR or INSTALL a
new power steering
pump as necessary.
REFER to Section 211 -
02 .
Symptom Chart—
Suspension Noise/Vibration Condition
Possible Sources Action
z Squeak or grunt— noise
from the front suspension,
occurs more in cold
ambient temperatures.
More noticeable over
rough roads or when
turning z
Front stabilizer
bar insulators. z
Under these conditions,
the noise is acceptable.
CHECK TSBs. Klj . 36 ba
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