2003 FORD MUSTANG wheel

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
32003 Mustang Workshop Manual
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GENERAL PROCEDURES
Flywheel Check
1. Check the flywheel surface for scoring, cracks or discoloration. Minor scratches or discoloration should be removed with a fine emery cloth.
SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Klj . 1 ba
12003 Mustang Workshop Manual
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GENERAL PROCEDURES
Flywheel Runout Check
1. Mount the special tool so that the indicator contact point rides on the clutch disc contact surface.
2. Turn the flywheel (6375); if the runout exceeds the maximum allowance, install a new flywheel.
SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Special Tool(s)
Dial Indicator/Magnetic Base
100-
D002 (D78P-4201- B) or
equivalent Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Dowels —Flywheel
Removal 1. NOTE: Take care not to damage the flywheel dowel holes or the surface areas around the
flywheel dowel during removal.
Remove the flywheel dowels by using a drift pin where the flywheel dowel is installed in an open
hole and a pair of locking pliers where the flywheel dowel is installed in a blind hole.
Installation 1. NOTE: Care should be taken to drive the flywheel dowel squarely into place until it is fully
seated and to not damage the surrounding surface areas.
Install all flywheel dowels by driving them into place using a brass or plastic mallet.
SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Dowels —
Flywheel Housing to Block
Removal 1. NOTE: Take care not to damage the flywheel housing to block dowel holes or the surface areas
around the flywheel housing to block dowel hole during removal.
Remove the two flywheel housing to block dowels using a drift pin where the flywheel housing
to block dowel is installed in an open hole and a pair of locking pliers where the flywheel
housing to block dowel is installed in a blind hole.
Installation 1. NOTE: Care should be taken to drive the flywheel housing to block dowel squarely into place
until it is fully seated without damaging the surrounding surface areas.
Install all flywheel housing to block dowels by driving them into place using a brass or plastic
mallet.
SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Klj . 1 ba
22003 Mustang Workshop Manual
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SPECIFICATIONS
SECTION 308-
01: Clutch 2003 Mustang Workshop Manual General Specifications
Item Specification
Pressure Plate
Pressure plate diameter (3.8L) 280 mm (11.0 in)
Pressure plate diameter 4.6L (2V) 280 mm (11.0 in)
Pressure plate diameter 4.6L (4V) 280 mm (11.0 in)
Clutch Disc
Clutch diameter (3.8L)
280 mm (11.0 in) Number of springs:
5 plain
Color identification:
none Clutch diameter (4.6L 2V)
280 mm (11.0 in) Number of springs:
4 plain
Color identification:
none Clutch diameter (4.6L 4V)
280 mm (11.0 in) Number of springs:
5 plain
Color identification:
no paint daub Fluid and Lubricants
Motorcraft Premium Long-
Life Grease
XG -1-C or equivalent ESA-
M1C75- B
Torque Specifications Description Nm lb-
ft Pressure plate to flywheel bolt (3.8L) 33 24
Pressure plate to flywheel bolts 4.6L (2V) 45 + 60° 33 + 60°
Pressure plate-
to-flywheel bolts 4.6L (4V) 45 + 60° 33 + 60° Klj . 1 ba
22003 Mustang Workshop Manual
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DESCRIPTION AND OPERATION
Clutch
The primary function of the clutch is to couple and uncouple engine power to the transmission upon
driver command. For additional information, refer to
Section 308 - 02 .
z The clutch is a single plate, dry friction clutch disc. The clutch disc has a splined hub (with
integral torsional dampening springs) which attaches the clutch disc to the input shaft.
z Engine output is coupled to the input shaft by the friction existing between the clutch disc
facings and the flywheel/clutch pressure plate assembly. The extent of this friction is directly
related to the composition of the facing material and the magnitude of the clamping force
exerted by the clutch pressure plate. These factors limit the amount of torque that can be
transmitted without slippage.
z The clamping force is obtained from a diaphragm spring contained within the clutch pressure
plate assembly. This force is developed during the attachment of the clutch pressure plate to
the flywheel.
z The clutch system is disengaged when the clutch pedal is depressed and engaged when the
clutch pedal is released. This displacement removes the spring load from the clutch pressure
plate and eliminates the coupling friction between the engine and the transmission.
z When the clutch pedal is depressed, a cable connected to the clutch release lever, hub and
bearing actuates the clutch pressure plate diaphragm spring, releasing pressure on the clutch
disc. This eliminates the engagement between the transmission and the engine.
SECTION 308-
01: Clutch 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Disc and Pressure Plate —
3.8L and 4.6L (2V) Engines
1. Remove the transmission. For additional information, refer to Section 308 - 03A (T5OD) or
Section 308 - 03B (TR3650).
2. CAUTION: Loosen the bolts evenly to prevent clutch pressure plate damage.
NOTE: If the parts are to be reused, mark the clutch pressure plate and the flywheel.
Remove the bolts and remove the clutch pressure plate and the clutch disc.
Installation
NOTE: Clean the clutch pressure plate and flywheel with a commercial alcohol- based solvent so
surfaces are free from oil film.
Do not use cleaners with a petroleum base. Do not immerse the clutch pressure plate in the solvent.
1. Position the clutch disc on the flywheel. zUsing the special tool, align the clutch disc.
SECTION 308-
01: Clutch 2003 Mustang Workshop Manual Special Tool(s)
Clutch Aligner
308-
020 (T74P-7137- K)
Material Item Specification
Premium Long Life Grease
XG
-1-C ESA-
M1C75- B Klj . 1 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_2308/S3B~us~en~ ...