2003 FORD MUSTANG manual transmission

Symptom Chart—
Transmission (Manual) and Transfer Case Noise/Vibration Condition
Possible Sources Action
z Clutch rattling noise—
occurs with clutch
engaged, noise
changes/disappears
with clutch pedal
depressed z
Flywheel bolts,
clutch housing bolts
or clutch pressure
plate bolts loose. z
TIGHTEN the bolts to
specifications. CHECK
the bolts for damage.
z Clutch squeaking
noise— noise is heard
when the clutch is
operated. Vehicle
moves slowly or
creeps when the clutch
is disengaged. Can
also be difficult to shift
into first and reverse
gear z
Pilot bearing seized
or damaged. z
INSTALL a new pilot
bearing. REFER to
Section 308 - 01 .
z Clutch squeaking
noise— occurs with
clutch pedal
depressed/released z
Worn clutch pedal
shaft or bushings. z
INSPECT the clutch
pedal for wear or
damage. REPAIR as
necessary. REFER to
Section 308 - 02 .
z Clutch whirring/rattle
noise— occurs when
clutch pedal is
depressed z
Worn, damaged or
misaligned clutch
release bearing. z
INSTALL a new clutch
release bearing.
REFER to Section 308 -
01 .
z Clutch grating/grinding
noise— occurs when
clutch pedal is
depressed z
Clutch pressure
plate fingers bent or
worn. z
INSPECT the clutch
pressure plate release
fingers. INSTALL a new
pressure plate as
necessary. REFER to
Section 308 - 01 .
z Contact surface of
clutch release
bearing worn or
damaged. z
INSTALL a new clutch
release bearing.
REFER to Section 308 -
01 .
z Clutch chatter— a
small amount of noise
when clutch pedal is
released at initial take-
off z
Clutch engagement. zAcceptable operating
condition.
z Clutch chatter/grabs—
in some cases a
shudder is felt. Occurs
with clutch pedal
depressed/released z
Damaged or worn
powertrain/driveline
mounts. z
INSPECT the
powertrain/drivetrain
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 Binding or dragging
plunger of the clutch
master cylinder or
slave cylinder. z
CHECK the master and
slave cylinder
operation. INSPECT
the components for
damage or wear.
INSTALL a new master
or slave cylinder as
necessary. REFER to Klj . 40 ba
702003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Section 308 - 02 .
z Grease or oil on the
clutch disc facing. z
CHECK the input shaft
seal and rear main oil
seal. REPAIR as
necessary. INSTALL a
new clutch disc.
REFER to Section 308 -
03A for T50D
transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Clutch disc surface
glazed or damaged. z
INSPECT the clutch
disc surface for a
glazed, hardened or
damage condition.
CARRY OUT a disc
check. INSTALL a new
clutch disc as
necessary. REFER to
Section 308 - 01 .
z Damaged or worn
clutch pressure
plate. z
INSPECT the clutch
pressure plate for wear
or damage. INSTALL a
new clutch pressure
plate as necessary.
REFER to Section 308 -
01 .
z Flywheel surface
damaged or glazed. z
INSPECT the flywheel
for damage or wear.
CARRY OUT a
flywheel runout check.
INSTALL a new
flywheel as necessary.
REFER to Section 303 -
01A for 3.8L engines or
Section 303 - 01B for
4.6L (2V) engines.
z Clutch chatter noise—
noise when clutch
pedal is released at
initial take- off. Clutch is
hard to engage and
disengage z
Pilot bearing worn,
damaged or not
correctly aligned in
bore. z
INSPECT the clutch
pressure plate release
fingers for uneven
wear, clutch
components burnt or a
seized pilot bearing.
INSTALL a new pilot
bearing as necessary.
REFER to Section 308 -
01 .
z Clutch vibration zLoose flywheel
bolts.
z Damaged or loose
clutch pressure
plate.
z Excessive flywheel
runout. z
Go To Pinpoint Test L .
z Transmission
rattling/clattering
noise— noise at idle or
on light acceleration
from a stop. Gear
selection difficult z
Gearshift lever joint
worn or damaged. z
INSTALL a new
gearshift lever. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions. Klj . 41 ba
702003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

z
Gearshift lever
loose. z
TIGHTEN the bolts to
specification. REFER to
Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Gearshift linkage
rods worn or
damaged. z
CHECK the linkage
bushings for wear.
INSTALL new linkage
rods as necessary.
REFER to the
appropriate workshop
manual for the service
procedures.
z Transmission
rattling/clattering
noise— occurs in
neutral or in gear, at
idle z
Incorrect fluid level
or fluid quality. z
CHECK that the
transmission is filled to
the correct level and
with the specified fluid.
REFER to Section 308 -
03A for T50D
transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transmission
rattling/clattering
noise— noise at idle in
neutral z
Worn or rough
reverse idler gear. z
CHECK the reverse
idler gear. REPAIR as
necessary. REFER to
Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Rough running
engine, cylinder
misfire. z
CHECK the ignition
system. CARRY OUT a
cylinder power test.
REFER to Section 303 -
00 .
z Excessive backlash
in gears z
CHECK the gear
backlash. ADJUST as
necessary. REFER to
Section 205 - 02A for
Ford 7.5 rear axles or
Section 205 - 02B for
Ford 8.8 integral axles.
z Worn countershaft
gears. z
REPAIR as necessary.
REFER to Section 308 -
03A for T50D
transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transmission whine—
a mild whine at
extreme speeds or
high rpm z
Rotating
gears/geartrain. z
Acceptable noise.
z Transmission whine—
a high pitched whine,
also described as a
squeal z
Transmission gears
are worn (high
mileage vehicle). z
Result of normal gear
wear. REPAIR as
necessary. REFER to
Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions. Klj . 42 ba
702003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

z
Mismatched gear
sets. z
INSPECT the gear sets
for an uneven wear
pattern on the face of
the gear teeth. REPAIR
as necessary. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Damaged or worn
transmission
bearing. z
INSPECT the
transmission bearings.
INSTALL new bearings
as necessary. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transmission
growling/humming—
noise occurs in the
forward gears. The
noise is more
prominent when the
gear is loaded. The
problem gear can be
located as the noise
occurs in a specific
gear position z
Gear is cracked,
chipped or rough. z
INSPECT the
transmission gears for
damage or wear.
INSTALL new gears as
necessary. REFER to
Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transmission
hissing— noise in
neutral or in forward
gears. As bearings
wear or break up, the
noise changes to a
thumping noise z
Damaged or worn
bearings. z
INSPECT the
transmission bearings.
INSTALL new bearings
as necessary. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transmission
knocking/thudding—
noise at low speeds in
forward gears z
Bearings with
damaged balls or
rollers or with pitted
and spalled races. z
INSPECT the
transmission bearings.
INSTALL new bearings
as necessary. REFER
to Section 308 - 03A for
T50D transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transmission
rumble/growl— noise at
higher speeds in
forward gears, more
pronounced in a
coast/deceleration
condition z
Incorrect driveline
angle. z
CHECK the driveline
angle. REPAIR as
necessary. REFER to
Section 205 - 00 .
z Driveshaft out of
balance or
damaged. z
CHECK the driveshaft
for damage, missing
balance weights or
undercoating. Using the
vibration analyzer (VA),
CHECK the driveshaft
balance. CARRY OUT
a driveline vibration
test. For additional Klj . 43 ba
702003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

information, REFER to
Section 205
- 00 .
REPAIR as necessary.
z Transmission
rumble/growl— noise at
all speeds in forward
gears, more
pronounced in a heavy
acceleration condition z
Damaged or worn
transmission
bearing or gears
(high mileage
vehicles). z
CHECK transmission
fluid for excessive
metal particles.
REPAIR as necessary.
REFER to Section 308 -
03A for T50D
transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Transfer case whine—
noise at all ranges z
Incorrect fluid level
or fluid quality. z
CHECK that the
transfer case is filled to
the correct level and
with the specified fluid.
REFER to Section 308 -
03A for T50D
transmissions or
Section 308 - 03B for
TR3650 transmissions.
z Worn oil pump. zDISASSEMBLE the
transfer case. CHECK
the oil pump for wear or
damage. REPAIR as
necessary.
z Under- inflated or
oversized tires. z
CONFIRM that the tires
and wheels are correct
for the vehicle. CHECK
that the tire inflation
pressures are correct.
z Transfer case
growl/rumble— noise at
all ranges (A small
amount of planetary
noise can be heard
when the transfer case
is operated in low
range.) z
Damaged or worn
bearings or
planetary gear. z
DISASSEMBLE the
transfer case. CHECK
the bearings or
planetary gear for wear
or damage. REPAIR as
necessary.
z Transfer case
scraping/grating—
noise at all ranges z
Excessively
stretched drive
chain hitting the
case. z
DISASSEMBLE the
transfer case. CHECK
the drive chain for wear
or damage. REPAIR as
necessary.
z Transfer case
howl/hum— noise at all
ranges or high range
only z
Worn or damaged
sun (input) gear,
clutch pack
(intermediate) gear
or output shaft gear. z
DISASSEMBLE the
transfer case. CHECK
the gears for wear or
damage. REPAIR as
necessary.
z Transfer case
howl/hum— noise at
low range only z
Worn or damaged
intermediate gear
and sliding gears
(clutch pack). z
DISASSEMBLE the
transfer case. CHECK
the gears for wear or
damage. REPAIR as
necessary.
z Transfer case
vibration— vibration felt
with vehicle in 4WD z
Transfer case
mounting.
z Driveshaft out of
balance.
z Excessive pinion z
Go To Pinpoint Test M . Klj . 44 ba
702003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

flange runout.
Symptom Chart—
Transmission (Automatic) Noise/Vibration Condition
Possible Sources Action
z Rattle— occurs
at idle or at
light
acceleration
from a stop z
Damaged engine or
transmission mounts. z
CHECK the
powertrain/drivetrain mounts
for damage. REPAIR or
INSTALL new mounts as
necessary.
z A loose front exhaust
pipe heat shield. z
REPAIR or INSTALL a new
heat shield as necessary.
z Loose inspection
plate or dust cover
plate. z
CHECK for loose bolts.
TIGHTEN to specifications.
REFER to Section 307 - 01 .
z Loose flex plate to
converter nuts. z
CHECK for loose nuts.
TIGHTEN to specifications.
REFER to Section 307 - 01 .
z Whine— pitch
increases with
vehicle speed.
Starts in first
and second
gear,
decreases or
goes away at
higher gears z
Damaged or worn low
one- way clutch.
z Damaged or worn
intermediate one- way
clutch.
z Friction elements.
z Damaged or worn
planetary or sun gear. z
INSPECT the transmission
for wear or damage. REPAIR
or INSTALL new components
as necessary. REFER to
Section 307 - 01 .
z Whine— the
pitch changes
with engine
speed z
A worn or damaged
accessory drive
component. z
CARRY OUT the Engine
Accessory Test. REPAIR or
INSTALL new components as
necessary.
z Incorrect fluid level. zCHECK that the transmission
is filled to the correct level.
ADD fluid as necessary.
REFER to Section 307 - 01 .
z Partially blocked filter. zINSPECT the filter. CLEAN or
INSTALL a new filter as
necessary. REFER to Section 307 - 01 .
z Worn or damaged
torque converter. z
CARRY OUT the torque
converter service and
replacement check. REFER
to Section 307 - 01 .
z Worn or damaged
front pump. z
INSPECT the front pump.
INSTALL a new front pump
as necessary. REFER to
Section 307 - 01 .
z Whine— pitch
changes with
vehicle speed z
Speedometer cable
or gears. z
REPAIR or INSTALL new
cables or gears as necessary.
z Whine/moan
type noise—
pitch increases
or changes
with vehicle
speed z
Damaged engine or
transmission mount. z
CHECK the
powertrain/drivetrain mounts
for damage. CARRY OUT
Powertrain/Drivetrain Mount Neutralizing in this section.
z U-joints worn or zINSPECT the U- joints for Klj . 45 ba
702003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

damaged.
wear or damage. INSTALL
new U-joints as necessary.
REFER to Section 205 - 01 .
z Damaged or worn
differential ring and
pinion. z
INSPECT the differential ring
and pinion for damage.
CARRY OUT the Checking
Tooth Contact Pattern and
Condition of the Ring and
Pinion component test in this
section. REPAIR or INSTALL
a new differential 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 Planetary gears
nicked or chipped. z
CHECK the planetary gears
for damage. INSTALL new
components as necessary.
REFER to Section 307 - 01 .
z Whistle— noise
is high pitched,
constant.
Changes in
pitch with
throttle position z
Hydraulic pressure in
the main control. z
INSPECT the main control.
REPAIR or INSTALL new
components as necessary.
REFER to Section 307 - 01 .
z Incorrect band/clutch
apply pressure. z
CARRY OUT the line
pressure tests. REPAIR or
INSTALL components as
necessary. REFER to Section 307 - 01 .
z Worn or damaged
torque converter. z
CARRY OUT the torque
converter service and
replacement check. REFER
to Section 307 - 01 .
z Clunk— occurs
when shifting
from PARK to
a drive or
reverse
position z
Damaged powertrain
mounts. z
INSPECT the powertrain
mounts for damage. INSTALL
new mounts as necessary.
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 Worn or galled
driveshaft slip yoke
splines. z
CLEAN and INSPECT the
splines of the yoke. INSTALL
a new slip yoke as necessary.
REFER to Section 205 - 01 .
z Worn friction
elements or
excessive clutch pack
end plate play. z
INSPECT the transmission
for wear. CHECK that all end
play and clearances are
within specification. REPAIR
or INSTALL new components
as necessary. REFER to
Section 307 - 01 . Klj . 46 ba
702003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

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
702003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...