2003 FORD MUSTANG brake

PINPOINT TEST C: CLUTCH DRAG loose or damaged? No
GO to
B2 .
B2 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 B3 .
B3 INSPECT PRESSURE PLATE
z
Remove the clutch pressure plate. Refer to
Section 308 - 01 .
z Inspect the clutch pressure plate. Refer to
Pressure Plate Check .
z Are 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 B4 .
B4 CHECK CLUTCH DISC
z
Carry out the clutch disc inspection procedure.
Refer to Disc Check .
z Is the clutch disc OK? Yes
GO to
B5 .
No
INSTALL a new clutch disc. REFER to
Section 308 - 01 . TEST the system for
normal operation. B5 INSPECT THE FLYWHEEL
z
Inspect the flywheel for damage and runout. Refer
to Flywheel Runout Check .
z Is the flywheel OK? Yes
GO to
B6 .
No
REPAIR or INSTALL a new flywheel
as necessary. REFER to Section 308 -
01 . TEST the system for normal
operation. B6 INSPECT THE INPUT SHAFT
z
INSPECT the input shaft for signs of wear or
damage.
z Are any signs of wear or damage present on
the input shaft? Yes
INSTALL a new input shaft. REFER to
Section 308
- 03A or
Section 308 - 03B .
No
VERIFY the customer concerns. GO
to Symptom Chart if necessary.
Test Step Result / Action to Take
C1 CHECK HIGH SHIFTING EFFORTS
z
Key in START position.
z Set parking brake.
z With the shift control selector in REVERSE, Yes
Clutch system OK.
No Klj . 8 ba
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GENERAL PROCEDURES
Disc Check
WARNING: Dust and dirt present on wheel brake and clutch assemblies may contain
asbestos fibers that are hazardous to health when made airborne by cleaning with compressed
air or by dry brushing. Failure to follow these instructions may result in personal injury.
WARNING: Wheel brake assemblies and clutch facings should be cleaned using a vacuum
cleaner recommended for use with asbestos fibers such as the brake automobile brake drum
system with vacuum. Dust and dirt from the vacuum should be disposed of in a manner that
prevents dust exposure such as sealed bags. The bag must be labeled according to OSHA
instructions and the trash hauler notified as to the bag's contents. Failure to follow these
instructions may result in personal injury.
WARNING: If a vacuum suitable for asbestos is not available, cleaning should be done
wet. If dust generation is still possible, technicians should wear government- approved toxic
dust purifying respirators. Failure to follow these instructions may result in personal injury.
WARNING: Grinding or sanding on the brake linings, pads, rotors, drums or clutch
facings should be done only while using correct exhaust- ventilated equipment. Failure to
follow these instructions may result in personal injury.
WARNING: OSHA requires areas where asbestos dust generation is possible to be
isolated and posted with warning signs. Only technicians concerned with carrying out brake or
clutch service should be present in the area. Failure to follow these instructions may result in
personal injury.
1. Check the clutch disc lining surface for hardening or the presence of oil.
2. Check for a worn clutch disc lining. Measure the minimum allowable depth to the rivet heads with a slide caliper.
SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Special Tool(s)
Brake/Automobile Brake Drum
System with Vacuum
164-
R3622 or equivalent Dial Indicator/Magnetic Base
100-
D002 (D78P-4201- B) or
equivalent Klj . 1 ba
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SPECIFICATIONS
SECTION 308-
02: Clutch Controls 2003 Mustang Workshop Manual General Specifications
Item Specification
Clutch System
System adjustment Self adjusting
Fluid and Lubricant
Super Premium SAE 10W-30
XO- 10W-30- BSP WSS-
M2C153- G
Torque Specifications Description Nm lb-
ft lb-
in Brake booster nuts 25 18 —
Brake pedal support bracket to cowl bolt 25 18 —
Clutch pedal retaining nut 40 30 —
Clutch release lever cable bracket screw (3.8L) 10 — 89
Clutch release lever cable to bulkhead screws 4 — 35
Clutch release lever cable to crossmember retaining screw 8 — 71
Clutch release lever cable to master cylinder retaining screw (4.6L) 8 — 71
Instrument panel reinforcement screws 9 — 80
Instrument panel steering column cover screws 9 — 80 Klj . 1 ba
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REMOVAL AND INSTALLATION
Clutch Pedal —
Quadrant and Pawl Assembly
Removal 1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414 -
01 .
2. Loosen the nut from inside the engine compartment.
3. Loosen the nuts from inside the vehicle.
4. Loosen the screw.
5. Disconnect the brake pedal position (BPP) switch electrical connector.
SECTION 308-
02: Clutch Controls 2003 Mustang Workshop Manual Klj . 1 ba
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6. Disconnect the brake pedal-
to-power brake booster push rod.
1. Remove the self- locking pin.
2. Remove the BPP switch from the brake master cylinder push rod.
3. Remove the brake master cylinder push rod spacers (2B129).
4. Remove the brake master cylinder push rod bushing (2474).
7. Disconnect the clutch pedal position (CPP) switch electrical connector.
8. Disconnect the deactivation switch connector from the wiring harness. Klj . 2 ba
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13. Remove the self-
adjusting mechanism.
14. Remove the self- adjusting mechanism shaft bushings.
Installation 1. NOTE: Before the installation of the clutch pedal shaft or clutch pedal, remove and inspect the
brake and clutch pedal bushings. Clean and lubricate with a light film of engine oil meeting Ford
specification WSS- M2C153-G and replace the brake and clutch pedal bushing if excessive wear
is evident.
To install, reverse the removal procedure. Klj . 4 ba
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4. Remove the front seat. For additional information, refer to
Section 501 - 10 .
5. Unhook the clutch release lever cable (7K553) from the clutch pedal adjuster quadrant (7L583).
6. Open the hood, remove the screws and the clutch release cable (7K553).
7. NOTE: On 4.6L vehicles only
Remove the bolt and the clutch release lever cable bracket from the brake master cylinder
(2140).
8. Raise the vehicle. For additional information, refer to Section 100 - 02 .
9. Remove the screw from the clutch release lever cable clamp. Klj . 2 ba
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9 7N232 Gear shift plate
10 7K201 Gear selector interlock sleeve
11 305078-
S Pin
12 7302 Selector body
13 7230 Gear shifter fork 3-
4 shift 14 7160 Output shaft bearing snap ring
15 7117 Second speed synchronizer thrust washer
16 7175 First and second gear synchronizer inner cone
17 7174 First and second gear synchronizer outer cone
18 7107 Synchronizer blocking ring
19 7A044 Synchronizer hub insert (also part of 7124)
20 7K218 First and second speed synchronizer hub ball
21 7061 Output shaft assembly
22 7109 Synchronizer hub insert spring (also part of
7124)
23 7124 Sleeve (also part of 7061)
24 7173 First gear bearing spacer
25 7127 First gear bearing
26 7100 First gear
27 7065 Output shaft rear bearing
28 7D234 Thrust bearing
29 7D235 Thrust washer
30 — Synchronizer hub (part of 7124)
31 7124 Synchronizer assembly
32 7B340 Third gear
33 7B369 Third speed bearing
34 7B320 Third speed gear bearing spacer
35 7064 Snap ring
36 7119 Thrust washer
37 7102 Second gear
38 7728 Second speed gear bearing spacer
39 7693 Countershaft front bearing seal
40 7F431 Countershaft bearing assembly
41 7113 Countershaft cluster gear
42 7L172 Countershaft rear bearing adjustment shim
43 7195 Countershaft rear bearing retainer
44 7C210 Bolt
45 7144 Fifth speed cluster gear
46 7M000 Reverse brake ring
47 7G042 Thrust washer
48 7059 Fifth speed synchronizer retaining snap ring
49 7L276 Oil pick-
up funnel Klj . 3 ba
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