2003 FORD MUSTANG brake

14. Remove the fifth speed synchronizer retaining snap ring, the thrust washer (7G042), the reverse
brake ring (7M000), and the synchronizer blocking ring (7107).
15. Remove the fifth speed cluster gear (7144), the synchronizer blocking ring (7107), the synchronizer assembly (7124), and the fifth gear shifter fork (7230) as an assembly.
16. Remove the reverse gearshift lever retaining clip.
17. NOTE: Do not remove the reverse gearshift lever (7K002) at this time.
Using a TORX® bit driver, remove the shift lever reverse pin (7K024). Klj . 5 ba
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21.
NOTE: If not done so previously, soak the blocking ring in transmission fluid for ten minutes.
Install the fifth speed cluster gear, the synchronizer blocking ring, the synchronizer assembly,
and the fifth gear shifter fork as an assembly.
22. CAUTION: To prevent component damage when installing the extension housing
(7A039), the alignment tab on the reverse brake ring (7M000) must engage the alignment
slot in the extension housing.
NOTE: If not done so previously, soak the blocking ring in transmission fluid for ten minutes.
Install the synchronizer blocking ring, the reverse brake ring, the thrust washer, and the fifth
speed synchronizer retaining snap ring.
23. Apply pipe sealant to the reversing lamp switch threads and install the switch.
24. Install the reverse gearshift lever retaining clip. Klj . 8 ba
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29. Apply a 3.2-
mm (1/8-in) bead of silicone rubber to the sealing surface on the extension housing.
30. Install the detent ball, the shifter detent spring, and the gearshift offset lever. 1. Coat the shifter detent spring with petroleum jelly and install it in the gearshift offset lever.
2. Lubricate the detent plate and install the detent ball in the neutral position on the plate.
3. Position the gearshift offset lever in the extension housing with the gear shift interlock
spring over the detent ball.
31. CAUTION: To prevent component damage, the alignment tab on the reverse brake
ring must align with the alignment slot in the extension housing.
NOTE: Verify that the oil pick- up funnel engages the fifth gear synchronizer.
Slide the gearshift offset lever and the extension housing into place as an assembly. Press
downward on the gearshift offset lever to compress the shifter interlock spring and push the
gearshift offset lever and extension housing into place. Klj . 10 ba
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DESCRIPTION AND OPERATION
Speed Control
The speed control system consists of the following components:
zspeed control actuator cable (9A825)
z deactivator switch
z output shaft sensor (OSS)
z speed control actuator switches (9C888)
z brake pedal position (BPP) switch (13480)
z speed control servo (9C735)
z clutch pedal position switch (manual transmission only)
SECTION 310-
03: Speed Control 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Speed Control
Refer to Wiring Diagrams Cell
31 , Speed Control for schematic and connector information.
Principles of Operation
The speed control system is designed to maintain vehicle speed above 48 km/h (30 mph). After the
ON switch is depressed, depressing the SET/ACCEL switch will activate the speed control servo. To
increase a set speed, either depress and hold for continuous acceleration, or momentarily tap the
SET/ACCEL switch for 1.6 km/h (1 mph) acceleration increments. To decrease a set speed, depress
and hold the COAST switch until the target speed is reached, or momentarily tap the COAST switch
for 1.6 km/h (1 mph) deceleration increments. When the speed control system has been disabled by
tapping the brake pedal, the RESUME switch can be depressed and the vehicle will return to the
original set speed if the vehicle is traveling over 48 km/h (30 mph) and the OFF switch has not been
depressed.
NOTE: The deactivator switch is provided as an additional safety feature. Normally, when the brake
pedal is depressed, an electrical signal from the brake lamp circuit to the speed control servo will
deactivate the system. Under increased brake pedal effort, the deactivator switch will open and
remove power to the speed control servo, releasing the throttle independent of the speed control
servo.
NOTE: The air bag sliding contract provides the electrical interface between the steering column wiring
and the speed control actuator switches in the steering wheel.
The inputs to the speed control servo are the:
zvehicle speed signal.
SECTION 310-
03: Speed Control 2003 Mustang Workshop Manual Special Tool(s)
Worldwide Diagnostic System
(WDS)
418-
F224,
New Generation STAR (NGS)
Tester
418- F052, or equivalent
diagnostic tool 73 Digital Multimeter or
equivalent
105-
R0051 Breakout Box, EEC-V Control
System 418-049, or equivalent
014- 00950 Klj . 1 ba
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z
speed control actuator switches.
z brake pedal position (BPP) switch.
z clutch pedal position (CPP) switch.
z deactivator switch.
The output of the speed control servo is the:
zspeed control actuator cable controlling the throttle position.
Inspection and Verification
NOTE: If any concerns are noted with the speedometer, stoplamps, or horn, address those concerns
by referring to their associated sections before continuing speed control diagnosis.
1. Verify the customer concern by operating the speed control system.
2. Visually inspect for obvious signs of mechanical and electrical damage.
3. If the fault is not visually evident, verify the symptom and GO to the Symptom chart.
Symptom Chart
NOTE: New speed control diagnostic software is available in Version 12 or higher for the diagnostic
tool. When using this software, it is necessary to use Next Generation Speed Control Adapter 007-
00586 with the diagnostic tool.
NOTE: Refer to the Wiring Diagrams for connector numbers stated in the Pinpoint Test.
Visual Inspection Chart Mechanical Electrical
z
Deactivator switch
z Speed control actuator cable not attached to throttle
z Speed control actuator cable not fully seated to the
engine bracket z
Central junction box (CJB)
Fuse:
„15 (15A)
„ 33 (15A)
„ 35 (15A)
z Battery junction box (BJB)
fuse:
„HORN (20A)
z Wiring harness
z Loose or corroded
connections
z Speed control actuator
switches
Symptom Chart Condition
Possible Sources Action
z The speed control is zCentral junction zGo To Pinpoint Test A . Klj . 2 ba
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inoperative
box (CJB) fuse
17 (15A), 33
(15A).
z Battery junction
box (BJB) fuse
HORN (20A).
z Circuitry.
z Deactivator
switch.
z Clutch pedal
position (CPP)
switch.
z Speed control
actuator switch.
z Speed control
servo.
z Powertrain
control module
(PCM).
z The set speed
fluctuates z
Circuitry.
z Speed control
servo.
z Powertrain
control module
(PCM). z
Go To Pinpoint Test B .
z Engine. zREFER to the Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
z The speed control
does not disengage
when the brakes are
applied z
Central junction
box (CJB) fuse
33 (15A).
z Circuitry.
z Brake pedal
position (BPP)
switch.
z Speed control
servo. z
Go To Pinpoint Test C .
z The speed control
does not disengage
when the clutch is
applied z
Cluch pedal
position (CPP)
switch.
z Speed control
servo. z
Go To Pinpoint Test D .
z The speed control
switch is
inoperative— COAST z
Speed control
actuator switch.
z Speed control
servo. z
Go To Pinpoint Test E .
z The speed control
switch is
inoperative—
SET/ACCEL z
Speed control
actuator switch.
z Speed control
servo. z
Go To Pinpoint Test F .
z The speed control
switch is
inoperative—
RESUME z
Speed control
actuator switch.
z Speed control
servo. z
Go To Pinpoint Test G .
z The speed control
switch is
inoperative— OFF z
Speed control
actuator switch.
z Speed control
servo. z
Go To Pinpoint Test H . Klj . 3 ba
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PINPOINT TEST C: THE SPEED CONTROL DOES NOT DISENGAGE
WHEN THE BRAKES ARE APPLIED
PINPOINT TEST D: THE SPEED CONTROL DOES NOT DISENGAGE
WHEN THE CLUTCH IS APPLIED B2 CHECK THE SPEED CONTROL
ACTUATOR CABLE z
NOTE: The speed control actuator cable
must be disconnected at both ends while
carrying out this test.
z Check the speed control actuator cable
for sticking or binding at the speed
control servo and throttle body.
z Is the speed control actuator cable
OK? Yes
GO to
B3 .
No
INSTALL a new speed control actuator cable;
REFER to Actuator Cable — Speed Control .
TEST the system for normal operation. B3 CHECK THE SPEED CONTROL SERVO
z
INSTALL a known good speed control
servo.
z Test drive the vehicle for correct
operation.
z Does the speed control operate
correctly? Yes
INSTALL a new speed control servo; REFER
to
Actuator — Speed Control Servo . TEST the
system for normal operation.
No
INSTALL a new PCM; REFER to Section 303 -
14 . TEST the system for normal operation.
Test Step Result / Action to Take
C1 CHECK THE BPP SWITCH CIRCUITRY
z
Key in OFF position.
z Disconnect: Speed Control Servo C122 .
z Measure the voltage between speed control servo C122 Pin 4,
Circuit 511 (LG), harness side and speed control servo C122
Pin 10, Circuit 1205 (BK), harness side, while depressing the
brake pedal.
z Is the voltage greater than 10 volts? Yes
INSTALL a new speed
control servo; REFER to
Actuator
— Speed
Control Servo . TEST
the system for normal
operation.
No
REPAIR Circuit 810
(RD/LG) and Circuit 511
(LG) as necessary.
TEST the system for
normal operation. Test Step Result / Action to Take
D1 CHECK THE CLUTCH PEDAL POSITION (CPP) SWITCH
z
Key in OFF position.
z Disconnect: CPP Switch C2072.
z Measure the resistance between CPP switch pin 2
(component side) and CPP switch pin 1 (component side), Yes
INSTALL a new speed
control servo; REFER to
Actuator
— Speed Control Klj . 10 ba
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