2003 FORD MUSTANG pinpoint test b

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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PINPOINT TEST M: TRANSFER CASE VIBRATION the system for normal operation.
No
GO to
L6 .
L6 CHECK THE FLYWHEEL BOLTS
z
Check for loose flywheel bolts.
z Are the bolts loose? Yes
TIGHTEN the bolts to
specifications. REFER to
Section 308 - 01 . TEST the system for
normal operation.
No
GO to L7 .
L7 CHECK THE FLYWHEEL SURFACE
z
Inspect the flywheel surface for wear or damage.
Check the flywheel runout.
z Is there any damage or excessive wear? Yes
INSTALL a new flywheel. TEST
the system for normal operation.
No
Clutch system normal. CONDUCT
a diagnosis on other suspect
systems.
Test Step Result / Action to Take
M1 INSPECT THE TRANSFER CASE
z
WARNING: The electrical power to the air suspension
system must be shut off prior to hoisting, jacking or towing
an air suspension vehicle. This can be accomplished by
turning off the air suspension switch. Failure to do so can
result in unexpected inflation or deflation of the air springs,
which can result in shifting of the vehicle during these
operations.
z Inspect the transfer case for loose or missing mounting bolts.
Check for fluid seepage between the transfer case and the
transmission.
z Are the mounting bolts missing or loose? Yes
TIGHTEN to
specifications or
INSTALL new bolts as
necessary. TEST the
system for normal
operation.
No
GO to
M2 .
M2 INSPECT THE REAR DRIVESHAFT
z
NOTE: Verify that the driveshaft and pinion flange index marks
are aligned.
z Inspect the driveshaft for missing weights, damage or
undercoating.
z Inspect the U- joints for freedom of movement.
z Check driveshaft runout and, if necessary, check the pinion
flange runout.
z Is the driveshaft or U- joints worn or damaged or
misaligned? Yes
REPAIR or INSTALL a
new driveshaft as
necessary. TEST the
system for normal
operation.
No
GO to
M3 .
M3 CHECK THE DRIVELINE ANGLES
z
Measure the rear driveshaft and pinion angles. Refer to Section 205 - 00 .
z Measure the front driveshaft and pinion angles. Refer to Section 205 - 00 .
z Are the driveline angles incorrect? Yes
REPAIR as necessary.
TEST the system for
normal operation.
No Klj . 62 ba
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not machine a new brake disc.
7. For vehicles with a two- piece hub and brake disc assembly:
z Match-mark before disassembly.
z Remove the brake disc.
z Using a die grinder with a mild abrasive (Scotch Brite® type), remove any rust or
corrosion from the hub and brake disc mounting surfaces.
z Align the match- marks and reinstall the brake disc on the hub.
8. CAUTION: Do not use a bench lathe to machine brake discs.
NOTE: The depth of cut must be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter
cuts will cause heat and wear. Heavier cuts will cause poor brake disc surface finish.
Using on- vehicle brake lathe, machine the brake discs. Follow the manufacturer's instructions.
After machining, make sure the brake disc still meets the thickness specification.
9. Using a dial indicator, verify that the brake disc lateral runout is now within vehicle specification.
10. Remove any metal chips.
11. Remove the hub adapter.
12. Remove any remaining metal chips from the machining operation.
13. CAUTION: Do not carry out this step on rear drum- in-hat brake discs.
For vehicles with a two- piece hub and a non drum- in-hat brake disc assembly:
z Remove the brake disc from the hub.
z Remove any remaining metal chips from hub and brake disc mounting surfaces and from
the ABS sensor.
z Apply High Temperature Nickel Anti- Seize Lubricant F6AZ-9L494-AA to the mounting
surfaces.
z Using the match- marks, mount the brake disc on the hub.
14. Install the caliper and check brake operation.
Symptom Chart Symptom Chart
Condition
Possible Sources Action
z The Brakes Pull or
Drift z
Tire air pressure.
z Wheel alignment.
z Brake pads.
z Brake components.
z Suspension
component. z
Go To Pinpoint Test A .
z The Red Brake
Warning Indicator Is z
Instrument cluster.
z Circuit. z
Go To Pinpoint Test B . Klj . 4 ba
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Always On
zParking brake.
z Brake fluid level.
z Vibration When
Brakes Are Applied z
Rear disc brakes.
z Front disc brakes. z
REFER to Section 100 -
04 .
z Brake Pedal Goes
Down Fast z
Brake fluid level. zFILL the brake master
cylinder reservoir.
BLEED the system.
z Air in system. zBLEED the system.
z Brake master
cylinder. z
PERFORM the brake
master cylinder
component test in this
section.
z The Brake Pedal
Eases Down Slowly z
Air in system. zBLEED the system.
REFER to Bleeding —
System in this section.
z Brake master
cylinder. z
PERFORM the brake
master cylinder
component test in this
section.
z Brake Lockup During
Light Brake Pedal
Force z
Disc brake
component.
z Parking brake
component.
z Anti- lock brake
control system. z
Go To Pinpoint Test C .
z Excessive/Erratic
Brake Pedal Travel z
Leak in hydraulic
system.
z Air in system.
z Disc brake caliper.
z Brake master
cylinder. z
Go To Pinpoint Test D .
z Brakes Drag zParking brake
component. z
REPAIR or INSTALL new
components as
necessary. REFER to
Section 206 - 05 .
z Disc brake caliper. zREPAIR or INSTALL a
new brake caliper as
necessary. REFER to
Section 206 - 03 and
Section 206 - 04 .
z Brake booster-to-
brake master
cylinder push rod
adjustment. z
ADJUST the push rod.
REFER to Section 206 -
07 .
z Brake master
cylinder. z
PERFORM the brake
master cylinder
component test in this
section.
z Excessive Brake
Pedal Effort z
Power brake
booster. z
PERFORM the brake
booster component test
in this section.
z Power brake
booster check
valve (2365). z
PERFORM the check
valve component test in
this section.
z Power brake
booster hose. z
REROUTE, REPAIR or
INSTALL a new brake Klj . 5 ba
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Pinpoint Tests
PINPOINT TEST A: THE BRAKES PULL OR DRIFT booster hose as
necessary.
z Red Brake Warning
Indicator Inoperative z
Circuit.
z Bulb. z
REFER to Section 413 -
01 .
z Brake Noise zDisc brake
component. z
MACHINE or INSTALL a
new brake component as
necessary. REFER to
Section 206 - 03 or
Section 206 - 04 .
z Hydro-Boost, No
Power Assist z
Power steering
pump.
z Linkage.
z Power steering
fluid flow.
z Hydro-boost unit. z
Go To Pinpoint Test E .
z Hydro-Boost Erratic
Operation, Sticks,
Binds or Grabs z
Supply hose.
z Hydro-boost unit. z
Go To Pinpoint Test F .
z Hydro-Boost Brake
System Operation
Suspect z
Leakage.
z Hydro-boost unit. z
Go To Pinpoint Test G .
Test Step Result / Action to Take
A1 CHECK THE TIRES
NOTE:
Check tire pressure with the brakes off.
z Check tires for uneven and excessive wear and for correct
pressure.
z Are the tires OK? Yes
GO to
A2 .
No
CORRECT as necessary.
RETEST for normal
operation. A2 CHECK THE ALIGNMENT
z
Check the caster, camber and toe. Refer to Section 204 -
00 . Yes
GO to
A3 .
No
CORRECT alignment as
necessary. REFER to Section 204 - 00 . RETEST for correct
operation. Klj . 6 ba
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PINPOINT TEST B: THE RED BRAKE WARNING INDICATOR IS
ALWAYS ON z
Is the alignment OK? A3 CHECK THE DISC BRAKE COMPONENTS
z
Check all disc brake calipers, anchor plate guide pins and
brake pads for binding, wear, damage, contamination and
correct installation.
z Are the disc brake calipers, anchor plate guide pins
and brake pads OK? Yes
GO to
A4 .
No
REPAIR or INSTALL new
components as necessary.
RETEST for normal
operation. A4 ROAD TEST THE VEHICLE
z
Road test the vehicle, and observe whether the drift
occurs with or without the brakes applied.
z Does the drift or pull occur with the brakes applied? Yes
REPAIR or INSTALL new
front disc brake caliper or
anchor plate guide pins on
the side opposite to the
direction of the drift or pull.
No
REPAIR or INSTALL new
front disc brake caliper or
anchor plate guide pins on
the side of the vehicle in the
direction of the drift or pull.
Test Step Result / Action to Take
B1 CHECK THE BRAKE MASTER CYLINDER FLUID
LEVEL SWITCH z
Key in OFF position.
z Disconnect: Brake Master Cylinder Fluid Level Switch
C124.
z Connect a fused jumper from C124- 2 circuit 977
(PK/WH) to C124- 3 circuit 128 (VT/YE). Yes
GO to
B2 .
No
INSTALL a new brake master Klj . 7 ba
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PINPOINT TEST C: BRAKE LOCKUP DURING LIGHT BRAKE PEDAL
FORCE z
Is the resistance greater than 10,000 ohms? No
REPAIR the ground short in
circuit 128 (VT/YE). TEST the
system for normal operation.
B6 CHECK DAYTIME RUNNING LIGHTS (DRL) MODULE
z
Disconnect: DRL Module C1030.
z Measure the resistance to ground at C124- 2.
z Is the resistance greater than 10,000 ohms? Yes
REPAIR the DRL module. TEST
the system for normal operation.
No
REPAIR the ground short in
circuit 22 (LB/BK) or 977
(VT/WH). TEST the system for
normal operation.
Test Step Result / Action to Take
C1 INSPECT THE TIRES
z
Inspect the tires for uneven or excessive
wear, correct pressure, correct size and
type.
z Are the tires OK? Yes
GO to
C2 .
No
CORRECT as necessary. RETEST for
normal operation. C2 CHECK THE BRAKE CALIPER
COMPONENTS z
Inspect the brake pads and brake discs for
wear, damage, contamination and correct
installation.
z Are the brake components OK? Yes
GO to
C3 .
No
CORRECT as necessary. RETEST for
normal operation. C3 CHECK THE PROPORTIONING VALVE
z
Install the gauges from the ABS brake and
pressure test kit on one front and one rear
bleeder screw.
z Apply 6895 kPa (1000 psi) to the front
brake system.
z Is the pressure in the rear system 3516- Yes
INSPECT the disc brake calipers and
INSTALL new calipers as necessary.
RETEST for normal operation.
No Klj . 9 ba
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PINPOINT TEST D: EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL
PINPOINT TEST E: HYDRO-
BOOST, NO POWER ASSIST 4481 kPa (510-
650 psi)? INSTALL a new proportioning valve.
RETEST for normal operation.
Test Step Result / Action to Take
D1 CHECK FOR SPONGY PEDAL
z
Key in ON position.
z Operate the brake pedal and note pedal feel.
z Does the pedal feel spongy? Yes
BLEED the brake system. REFER to
Bleeding —
System in this section.
RETEST for normal operation.
No
GO to D2 .
D2 CHECK THE BRAKE PEDAL
z
Inspect the brake pedal and bracket for
binding, obstruction or damage.
z Is the brake pedal OK? Yes
GO to
D3 .
No
REPAIR or INSTALL a new brake pedal as
necessary. RETEST for normal operation. D3 CHECK THE BRAKE COMPONENTS
z
Inspect the calipers bolts, anchor plate bolts
and anti- rattle springs for binding, damage,
contamination and correct installation.
z Are the bolts and springs OK? Yes
GO to
D4 .
No
REPAIR or INSTALL new components as
necessary. RETEST for normal operation. D4 CHECK THE BOOSTER AND MASTER
CYLINDER z
Check the power brake booster and brake
master cylinder for correct installation and
correct push rod adjustment. Refer to
Section 206 - 06 and to Section 206 - 07 .
z Are the power brake booster and the
brake master cylinder OK? Yes
INSPECT the front wheel bearings for
wear, damage and correct installation and
the rear axle end play. CORRECT as
necessary. RETEST for normal operation.
No
CORRECT as necessary. RETEST for
normal operation.
Test Step Result / Action to Take
E1 CHECK FLUID LEVEL IN POWER STEERING
PUMP z
Check fluid level in power steering pump.
z Is level within specification? Yes
GO to
E2 .
No
CHECK for leakage of power steering
fluid. ADD fluid as necessary. E2 CHECK ACCESSORY DRIVE BELT Klj . 10 ba
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