2003 FORD MUSTANG brake

closing/opening
the window
z Squeak— heard
outside of vehicle
when
closing/opening
the door z
Exhaust shield
rubbing against
the chassis or
exhaust pipe. z
CHECK the exhaust system.
REPAIR as necessary. REFER
to Section 309 - 00 .
z Squeak— occurs
with initial brake
pedal application z
Disc brake pads. zUnder certain conditions,
asbestos free pads can
generate a squeak noise. This
noise is normal and does not
indicate a concern.
z Squeak— a
constant noise
that occurs with
brake pedal
applications z
Damaged or
worn disc brake
pads. z
INSPECT the pads for oil,
grease or brake fluid
contamination. CHECK for
glazed linings. A brake disc with
hard spots will also cause a
squeak type noise. REPAIR or
INSTALL new pads as
necessary. REFER to Section 206 - 03 for front disc brakes and
Section 206 - 04 for rear disc
brakes.
z Squeak— noise
occurs over
bumps or when
turning z
Worn control
arm bushings. z
INSPECT the control arm
bushings. Spray with lubricant
and CARRY OUT a "bounce
test" to determine which
bushing. REPAIR as necessary.
REFER to Section 204 - 01 .
z Worn or
damaged shock
absorber/strut. z
INSPECT the shock absorber
for damage. CARRY OUT a
"bounce test" to isolate the
noise. INSTALL a new shock
absorber/strut as necessary.
REFER to Section 204 - 01 for
the front shock absorber/strut or
Section 204 - 02 for the rear
shock absorber/strut.
z Rattle— heard
when
closing/opening
the door or
window z
Loose internal
door
mechanism,
bracket or
attachment. z
REPEAT the motion or CARRY
OUT a "tap test" to duplicate the
noise. INSPECT the door for
loose components. TIGHTEN
loose components or USE the
Rotunda Squeak and Rattle Kit
to isolate any rattling
components.
z Rattle — GT
models only,
noise occurs from
the rear of the
vehicle z
A loose or under
torqued shock
damper
attaching nut. z
VERIFY the torque on the
shock damper- to-axle nuts is 63
Nm (46 lb- ft). VERIFY the
torque for the shock damper- to-
rail bracket nuts is 90 Nm (66
lb- ft). Do not over torque.
TIGHTEN as necessary.
z Squeak or rattle—
heard inside the
vehicle over rough
roads/bumps z
Misaligned glove
compartment
door/hinge. z
ALIGN the glove compartment
door.
z Instrument panel
trim loose or z
INSPECT the instrument panel
trim for missing or loose clips or Klj . 32 ba
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01 .
z Damaged or
worn suspension
components. z
INSPECT the suspension
components for wear or
damage. REPAIR as
necessary.
z Loose wheel
nuts. z
CHECK the wheel nuts.
TIGHTEN to specification.
REFER to Section 204 -
04 .
z Damaged or
uneven tire wear. z
SPIN the tire and CHECK
for abnormal tire wear or
damage. INSTALL a new
tire as necessary. REFER
to Section 204 - 04 .
z Tire shimmy or
shake— occurs at
lower speeds z
Wheel/tire out of
balance. z
BALANCE the wheel/tire
assembly.
z Uneven tire wear. zCHECK for abnormal tire
wear. INSTALL a new tire
as necessary. REFER to
Section 204 - 04 .
z Excessive radial
runout of wheel
or tire. z
CARRY OUT a radial
runout test of the wheel
and tire. INSTALL a new
tire as necessary. REFER
to Section 204 - 04 .
z Worn or
damaged wheel
studs or
elongated stud
holes. z
INSPECT the wheel studs
and wheels. INSTALL new
components as necessary.
REFER to Section 204 - 01
for the front wheels or
Section 204
- 02 for the rear
wheels.
z Excessive lateral
runout of the
wheel or tire. z
CARRY OUT a lateral
runout test of the wheel
and tire. CHECK the
wheel, tire and hub.
REPAIR or INSTALL new
components as necessary.
z Foreign material
between the
brake disc and
hub or in the
brake disc fins. z
CLEAN the mounting
surfaces of the brake disc
and hub. CHECK the
brake disc fins for material.
z High speed shake or
shimmy—occurs at
high speeds z
Excessive wheel
hub runout.
z Damaged or
worn tires.
z Damaged or
worn wheel
bearings.
z Worn or
damaged
suspension or
steering linkage
components.
z Brake disc or
drum imbalance. z
Go To Pinpoint Test K . Klj . 39 ba
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Pinpoint Tests
The pinpoint tests are a step-by-
step diagnostic process designed to determine the cause of a z
Bump—occurs
when shifting
from PARK to
a drive or
reverse
position.
Similar to
Clunk but with
no sound z
Initial gear
engagement. z
Acceptable condition.
z Buzz or hiss zIncorrect driveline
angles. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to Section 205 - 00 .
z Worn or damaged
main control
solenoids or valves. z
Using a transmission tester,
ACTIVATE the solenoids to
duplicate sound. INSTALL
new components as
necessary. REFER to Section 307 - 01 .
z Vibration— a
high frequency
(20–80 Hz) that
is felt through
the seat or
gear shifter.
Changes with
engine speed z
Transmission cooler
lines grounded out. z
CHECK the transmission
cooler lines. REPAIR as
necessary.
z Flexplate to torque
converter nuts loose. z
CHECK the flexplate nuts.
TIGHTEN to specification.
REFER to Section 307 - 01 .
z Fluid filler tube
grounded out. z
CHECK the fluid filler tube.
REPAIR as necessary.
z Shift cable incorrectly
routed, grounded out
or loose. z
CHECK the shift cable.
REPAIR as necessary.
Section 307 - 05 .
z Shutter or
chatter—
occurs with
light to medium
acceleration
from low
speeds or a
stop z
Electrical
inputs/outputs.
z Vehicle wiring
harness.
z Incorrect
inputs/outputs from
the powertrain control
module (PCM), digital
transmission range
(TR) sensor, brake
pedal position (BPP)
sensor, throttle
position (TP) sensor,
transmission speed
sensor (TSS), output
speed shaft (OSS)
sensor or the torque
converter clutch
(TCC). z
CARRY OUT a Torque
Converter Clutch Operation
Test. RUN on- board
diagnostics or self- test.
REFER to Section 307 - 01 .
CLEAR the DTC's, ROAD
TEST and RERUN on- board
diagnostics or self- test. Klj . 47 ba
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condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the
steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is
necessary to remove various vehicle components to gain access to the component requiring testing.
Reinstall all components after verifying system operation is normal.
PINPOINT TEST A: BRAKE VIBRATION/SHUDDER
Test Step Result / Action to Take
A1 ROAD TEST THE VEHICLE—
LIGHT BRAKING z
Check that the wheel and tires are correct for the vehicle.
Inspect the tires for abnormal wear patterns.
z Road test the vehicle. Warm the brakes by slowing the vehicle
a few times from 80– 32 km/h (50 to 20 mph) using light braking
applications. At highway speeds of 89–97 km/h (55- 60 mph),
apply the brake using a light pedal force.
z Is there a vibration/shudder felt in the steering wheel, seat
or brake pedal? Yes
GO to
A4 .
No
GO to A2 .
A2 ROAD TEST THE VEHICLE—
MODERATE TO HEAVY
BRAKING z
Road test the vehicle. At highway speeds of 89–97 km/h (55- 60
mph), apply the brake using a moderate to heavy pedal force.
z Is there a vibration/shudder? Yes
For vehicles with ABS,
GO to
A3 . For vehicles
with standard brakes,
GO to A4 .
No
Vehicle is OK. VERIFY
condition with customer.
TEST the vehicle for
normal operation. A3 NORMAL ACTUATION OF THE ABS SYSTEM DIAGNOSIS
z
During moderate to heavy braking, noise from the hydraulic
control unit (HCU) and pulsation in the brake pedal can be
observed. Pedal pulsation coupled with noise during heavy
braking or on loose gravel, bumps, wet or snowy surfaces is
acceptable and indicates correct functioning of the ABS
system. Pedal pulsation or steering wheel nibble, (frequency is
proportioned to the vehicle speed) indicates a concern with a
brake or suspension component.
z Is the vibration/shudder vehicle speed sensitive? Yes
GO to
A5 .
No
The brake system is
operating correctly. A4 APPLICATION OF THE PARKING BRAKE
z
NOTE: Begin at the front of the vehicle unless the vibration or
shudder has been isolated to the rear.
z This test is not applicable to vehicles with drum- in-hat type
parking brakes. For vehicles with drum- in-hat parking brakes,
proceed to the next test. For all other vehicles, apply the
parking brake to identify if the problem is in the front or rear
brake. At highway speeds of 89–97 km/h (55- 60 mph), lightly
apply the parking brake until the vehicle slows down. Release
the parking brake immediately after the test.
z Is there a vibration/shudder? Yes
GO to
A7 .
No
GO to A5 .
A5 CHECK THE FRONT WHEEL BEARINGS
z
Check the front wheel bearings. Refer to Wheel Bearing Check in this section.
z Are the wheel bearings OK? Yes
GO to
A6 . Klj . 48 ba
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PINPOINT TEST B: ENGINE TICKING NOISE No
INSPECT the wheel
bearings. ADJUST or
REPAIR as necessary.
TEST the system for
normal operation.
A6 CHECK THE FRONT SUSPENSION
z
Check the front suspension for:
zBroken or loose bolts.
z Damaged springs.
z Worn or damaged upper and lower control arm
bushings.
z Loose or rough front bearings.
z Uneven tire wear.
z Are all the suspension components in satisfactory
condition? Yes
GO to
A7 .
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation. A7 RESURFACE THE FRONT BRAKE DISCS
z
CAUTION: Do not use a bench lathe to machine brake
discs.
z NOTE: Follow the manufacturer's instructions to machine the
brake discs. After machining, make sure the brake disc meets
the thickness specification.
z Refer to Brake Disc Machining in this section. Resurface the
front brake discs. Road test the vehicle.
z Is the vibration/shudder present? Yes
GO to
A8 .
No
Vehicle is OK. A8 CHECK THE REAR SUSPENSION
z
Check the rear suspension for:
zBroken or loose bolts.
z Damaged or worn springs or spring bushings.
z Worn or damaged upper and lower control arm
bushings.
z Worn or damaged trailing arms.
z Loose or rough rear bearings.
z Uneven tire wear.
z Are all the suspension components in satisfactory
condition? Yes
GO to
A9 .
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation. A9 RESURFACE THE REAR BRAKE DISC OR DRUM
z
CAUTION: Do not use a bench lathe to machine brake
discs.
z NOTE: Follow the manufacturers instructions to machine the
brake discs. After machining, make sure the brake disc meets
the thickness specification.
z Refer to Brake Disc Machining in this section. Resurface the
rear brake discs or drums. Road test the vehicle.
z Is the vibration/shudder present? Yes
CHECK the front
suspension for wear or
damage. RESURFACE
the front brake discs.
TEST the system for
normal operation.
No
Vehicle is OK.
Test Step Result / Action to Take
B1 CHECK FOR TICKING NOISE AT THE FUEL
RAIL z
Disconnect the first fuel line clip. Yes Klj . 49 ba
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z
Are there signs of visual runout? J5 RADIAL RUNOUT CHECK ON THE TIRE
z
Measure the radial runout of the wheel and tire assembly. A
typical specification for total radial runout is 0.045 inch.
z Is the radial runout within specifications? Yes
GO to
J8 .
No
GO to J6 .
J6 RADIAL RUNOUT CHECK ON THE WHEEL
z
Measure the radial runout of the wheel. A typical specification for
total radial runout is 0.045 inch.
z Is the radial runout within specifications? Yes
INSTALL a new tire.
TEST the system for
normal operation.
No
GO to
J7 .
J7 CHECK THE HUB/BRAKE DISC OR DRUM PILOT RUNOUT OR
BOLT CIRCLE RUNOUT z
Measure the pilot or bolt circle runout. A typical specification for
radial runout is:
zPilot runout— less than 0.15 mm (0.006 inch).
z Bolt circle runout— less than 0.38 mm (0.015 inch).
z Is the radial runout within specifications? Yes
INSTALL a new wheel.
TEST the system for
normal operation.
No
REPAIR or INSTALL
new components as
necessary. REFER to
Section 204
- 01 for the
front wheels or Section 204 - 02 for the rear
wheels. J8 LATERAL RUNOUT CHECK ON THE TIRE
z
Measure the lateral runout of the wheel and tire assembly. A
typical specification for total lateral runout is 1.14 mm (0.045
inch). Yes
Wheel and tires OK.
CONDUCT diagnosis
on other suspect
systems. Klj . 57 ba
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PINPOINT TEST K: HIGH SPEED SHAKE OR SHIMMY z
Is the lateral runout within specifications? No
GO to
J9 .
J9 LATERAL RUNOUT CHECK ON THE WHEEL
z
Measure the lateral runout of the wheel. A typical specification for
total radial runout is 1.14mm (0.045 inch.
z Is the lateral runout within specifications? Yes
INSTALL a new tire.
TEST the system for
normal operation.
No
GO to
J10 .
J10 CHECK THE FLANGE FACE LATERAL RUNOUT
z
Measure the flange face lateral runout. A typical specification for
lateral runout is:
zHub/brake disc— less than 0.13 mm (0.005 inch).
z Axle shaft— less than 0.25 mm (0.010 inch).
z Is the lateral runout within specifications? Yes
INSTALL a new wheel.
TEST the system for
normal operation.
No
REPAIR or INSTALL
new components as
necessary. REFER to
Section 204
- 01 for the
front wheels or Section 204 - 02 for the rear
wheels. Test Step Result / Action to Take
K1 CHECK FOR FRONT WHEEL BEARING ROUGHNESS
z
Chock the rear wheels.
z Raise and support the front end of the vehicle so that the front
wheel and tire assemblies can spin.
z Spin the front tires by hand. Refer to Wheel Bearing Check in
this section.
z Do the wheel bearings feel rough? Yes
INSPECT the wheel
bearings. REPAIR as
necessary. TEST the
system for normal
operation.
No
GO to
K2 .
K2 CHECK THE END PLAY OF THE FRONT WHEEL BEARINGS
z
Check the end play of the front wheel bearings. Refer to
Section 204 - 01 .
z Is the end play OK? Yes
GO to
K3 .
No
ADJUST or REPAIR as
necessary. TEST the
system for normal Klj . 58 ba
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PINPOINT TEST L: CLUTCH VIBRATION appropriate workshop manual for the service procedures.
z Secure the brake drums (if so equipped), by installing wheel
hub bolt nuts, reversed.
z Carefully accelerate the drivetrain while checking for vibration.
z Is the vibration present? assemblies as necessary.
TEST the system for
normal operation.
Test Step Result / Action to Take
L1 CHECK ENGINE COMPONENTS FOR GROUNDING
z
NOTE: Make sure the clutch is the cause of the
vibration concern. The vibration should occur during
clutch operation. The clutch can also be difficult to
engage or disengage. Eliminate all related systems
before checking the clutch components.
z NOTE: Check the driveline angles and driveshaft
runout before disassembling the clutch system. Refer
to Section 205 - 00 for the correct driveline angle
specifications.
z Check the powertrain/drivetrain mounts, exhaust
manifolds or other engine components for grounding
on the chassis.
z Are any mounts or engine components
grounded? Yes
REPAIR as necessary. TEST the
system for normal operation.
No
GO to
L2 .
L2 CHECK THE ACCESSORY DRIVE
z
Remove the accessory drive belt.
z Does the vibration stop with the accessory drive
belt removed? Yes
DIAGNOSE the accessory drive
components.
No
GO to
L3 .
L3 CHECK FOR LOOSE CLUTCH PRESSURE PLATE
BOLTS z
Check for loose clutch pressure plate bolts. Inspect
the clutch pressure plate for damage or for material
between the pressure plate and flywheel.
z Are there any loose bolts or damage? Yes
TIGHTEN the bolts to
specifications or if damaged,
INSTALL a new clutch pressure
plate. REFER to
Section 308 - 01 .
TEST the system for normal
operation.
No
GO to L4 .
L4 CHECK THE CLUTCH DISC SPRINGS
z
Check for worn, broken or loose clutch disc springs.
z Are the clutch springs worn, broken or loose? Yes
INSTALL a new clutch disc.
REFER to
Section 308 - 01 . TEST
the system for normal operation.
No
GO to L5 .
L5 CHECK THE CLUTCH DISC SPLINES
z
Inspect the clutch disc splines for damage or wear.
z Is there damage or wear? Yes
INSTALL a new clutch disc.
REFER to
Section 308 - 01 . TEST Klj . 61 ba
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