2003 FORD MUSTANG wheel alignment

PINPOINT TEST H: DTC C1233 (LF), C1234 (RF), C1235 (RR), C1236
(LR), ANTI-
LOCK BRAKE SENSOR INPUT SIGNAL MISSING Test Step Result / Action to Take
G1 CHECK THE VEHICLE
COMPONENTS z
Check for correct wheel and tire
size, front- to-rear and side- to-
side.
z Check for excessive bearing
end play.
z Check the anti- lock brake
sensor indicator for a
deformation or missing teeth.
z Are the conditions OK? Yes
GO to
G2 .
No
REPAIR as necessary. CLEAR the DTCs. REPEAT the
self- test. G2 TEST DRIVE THE VEHICLE
z
Enter the following diagnostic
mode on the diagnostic tool:
CLEAR the DTCs.
z Key in OFF position.
z Key in ON position.
z Test drive the vehicle over 24
kph (15 mph).
z Enter the following diagnostic
mode on the diagnostic tool:
Retrieve DTCs.
z Is DTC C1222 retrieved? Yes
INSTALL a new anti-
lock brake control module; REFER
to Module . REPEAT the self-
test.
No
If another DTC is retrieved, GO to the Anti- Lock Brake
Control Module Diagnostic Trouble Code (DTC) index.
If no DTCs are retrieved, the system is OK. Test Step Result / Action to Take
H1 CHECK THE SUSPECT ANTI-
LOCK BRAKE
SENSOR z
Check the suspect anti- lock brake sensor
mounting.
z Check the suspect anti- lock brake sensor for
excessive dirt build up, obstructions, and
damage.
z Is the suspect anti- lock brake sensor and
mounting OK? Yes
GO to
H2 .
No
REPAIR as necessary. CLEAR the
DTCs. REPEAT the self-test. H2 CHECK THE SUSPECT ANTI-
LOCK BRAKE
SENSOR INDICATOR z
Check the suspect anti- lock brake sensor
indicator for corrosion, nicks, bridged teeth,
damaged teeth, correct mounting, and alignment
with the anti- lock brake sensor.
z Check the air gap and bearing end play.
z Is the suspect anti- lock brake sensor
indicator OK? Yes
GO to
H3 .
No
INSTALL a new anti- lock brake sensor
indicator; REFER to Sensor — Front or
Sensor — Rear . CLEAR the DTCs.
REPEAT the self- test. H3 CHECK THE ANTI-
LOCK BRAKE SENSOR
OUTPUT z
Key in ON position.
z Enter the following diagnostic mode on the
diagnostic tool: CLEAR the DTCs..
z Key in OFF position.
z Key in ON position. Yes
INSTALL a new anti-
lock brake control
module; REFER to Module . REPEAT
the self- test. Klj . 12 ba
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column bearing(s).
bearing(s). REFER to
Section 211 - 04 .
z Loose, worn or
damaged lower
steering column shaft
U-joint(s). z
INSTALL a new lower
steering column shaft.
REFER to Section 211 - 04 .
z Wander zUnevenly loaded or
overloaded vehicle. z
INFORM the
customer of incorrect
vehicle loading.
z Loose, worn or
damaged front wheel
spindle tie- rod. z
GO to the Tie- Rod
Articulation Torque
Component Test.
z Loose, worn or
damaged tie- rod ends. z
GO to the Steering
Linkage Component
Test.
z Loose or damaged
steering gear mounting
bolts. z
INSTALL new or
TIGHTEN bolts.
REFER to Section 211 - 02 .
z Loose lower steering
column shaft U- joint
bolts. z
TIGHTEN the bolts.
REFER to Section 211 - 04 .
z Loose, worn or
damaged lower
steering column shaft
U-joints. z
INSTALL a new lower
steering column shaft.
REFER to Section 211 - 04 .
z Loose, worn or
damaged steering
column bearing(s). z
INSTALL new
steering column
bearings. REFER to
Section 211 - 04 .
z Suspension
components. z
REFER to Section 204 - 00 for suspension
system diagnosis and
testing.
z Drift/Pull zUnevenly loaded or
overloaded vehicle. z
INFORM the
customer of incorrect
vehicle loading.
z Wheel alignment. zCHECK the wheel
alignment. ADJUST
as required. REFER
to Section 204 - 00 .
z Loose, worn or
damaged front wheel
spindle tie- rod. z
GO to the Tie- Rod
Articulation Torque
Component Test.
z Loose, worn or
damaged tie- rod ends. z
GO to the Steering
Linkage Component
Test.
z Suspension
components. z
REFER to Section 204 - 00 for suspension
system diagnosis and
testing.
z The steering gear valve
effort out of balance. z
GO to Steering Gear
Valve Component
Test in this section.
z Check the brake
system for proper z
REFER to Section 206 - 00 . Klj . 6 ba
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operation.
z Incorrect
frame/underbody
alignment. z
CORRECT as
required. REFER to
Frame Dimension
Manual.
z Feedback zLoose, worn or
damaged front wheel
spindle tie- rod. z
GO to the Tie- Rod
Articulation Torque
Component Test.
z Loose, worn or
damaged tie- rod ends. z
GO to the Steering
Linkage Component
Test.
z Loose or damaged
steering gear insulators
or bolts. z
INSTALL new or
TIGHTEN the
retaining bolts.
REFER to Section 211 - 02 .
z Loose lower steering
column shaft U- joint
bolts. z
TIGHTEN the bolts.
REFER to Section 211 - 04 .
z Loose suspension
bushings, fasteners or
ball joints. z
INSTALL new
suspension
components as
necessary. REFER to
Section 204 - 01 .
z Worn or damaged
steering column
bearing(s). z
INSTALL new
steering column
bearing(s). REFER to
Section 211 - 04 .
z Poor
Returnability/Sticky
Steering z
Binding lower steering
column shaft U- joints. z
INSTALL a new lower
steering column shaft.
REFER to Section 211 - 04 .
z Loose, worn or
damaged front wheel
spindle tie- rod. z
GO to the Tie- Rod
Articulation Torque
Component Test.
z Loose, worn or
damaged tie- rod ends. z
GO to the Steering
Linkage Component
Test.
z Suspension
components. z
REFER to Section 204 - 00 for suspension
system diagnosis and
testing.
z Binding steering
column bearing(s). z
INSTALL new
steering column
bearing(s). REFER to
Section 211 - 04 .
z Shimmy zLoose, worn or
damaged tie- rod end. z
GO to the Steering
Linkage Component
Test.
z Loose, worn or
damaged front wheel
spindle tie- rod. z
GO to the Tie- Rod
Articulation Torque
Component Test.
z Suspension
components. z
REFER to Section 204 - 00 for suspension
system diagnosis and
testing. Klj . 7 ba
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11. Turn (or have an assistant turn) the steering wheel slightly in both directions and release quickly
while watching the pressure gauge.
zThe pressure reading should move from the normal back pressure reading and snap
back as the steering wheel is released.
z If the pressure returns slowly or sticks, the rotary valve in the steering gear is sticking or
the steering column is binding. Check the steering column and linkages before servicing
the steering gear.
Tie- Rod Articulation Torque
1. NOTE: This check may be done with the steering gear on or off the vehicle.
Disconnect the tie- rod end from the front wheel spindle. For additional information, refer to
Section 211 - 02 .
2. Move the front wheel spindle tie- rod back and forth three times.
3. Hook the special tool 211- 034 (T74P-3504-Y) over the tie-rod end or the threaded portion of the
front wheel spindle tie- rod and measure the force required to move the front wheel spindle tie-
rod. Refer to Tie- Rod Articulation Torque in General Specifications in this section.
4. If the force required to move the front wheel spindle tie- rod does not meet the specifications,
install a new front wheel spindle tie- rod. For additional information, refer to Section 211 - 02 .
Steering Gear Valve 1. With the vehicle in motion, place the transmission in NEUTRAL and turn the engine OFF. zIf the vehicle does not pull with the engine OFF, install a new steering gear. For
additional information, refer to Section 211 - 02 .
2. If the vehicle pulls with the engine OFF, cross- switch the front wheels.
3. If the vehicle pulls to the opposite side, cross- switch the front and rear wheels on the same side.
4. If the vehicle pull direction does not change, check the front suspension components, wheel alignment and frame alignment. For additional information, refer to Section 204 - 00 or frame
dimensions manual. Klj . 10 ba
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2. Install the steering gear into the special tools.
3. Clean the exterior of the steering gear with solvent. If necessary, drain any excess power
steering fluid.
4. Inspect the steering gear housing for cracks and other damage. If necessary, install a new steering gear.
5. Verify the power steering gear input shaft bearing rotates freely. If necessary, install a new steering gear.
6. Place an alignment mark on the tie- rod ends, nuts and front wheel spindle tie- rods. Remove the
tie- rod ends and nuts.
7. CAUTION: Use care not to damage the front suspension steering ball stud dust
seals. If the front suspension steering ball stud dust seals are damaged, this will allow
contamination into the steering gear and cause leakage.
Remove the clamps and the two front suspension steering ball stud dust seals.
zDiscard any clamps that are damaged or excessively corroded.
z Discard any front suspension steering ball stud dust seals that are damaged. Klj . 2 ba
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PINPOINT TEST E: CLUTCH RELATED VIBRATIONS z
Inspect the flywheel for damage and
runout. Refer to Flywheel Runout Check .
z Is flywheel OK? Yes
GO to
D6 .
No
TIGHTEN, RESURFACE or INSTALL a new
flywheel as necessary. REFER to Section 308 -
01 . TEST the system for normal operation.
D6 INSPECT RELEASE LEVER
INTERFACE TO PIVOT STUD z
Inspect the release lever and the pivot
stud for damage or misalignment.
z Are there any signs of damage
present or misalignment between the
release lever and pivot stud? Yes
INSTALL a new pivot stud and release lever.
REFER to
Section 308 - 01 . TEST the system
for normal operation.
No
VERIFY customer concern. GO to Symptom Chart if necessary.
Test Step Result / Action to Take
E1 CHECK FOR ENGINE COMPONENT
GROUNDING z
Raise the vehicle on a hoist. Refer to
Section 100 - 02 .
z Check the engine and transmission
mounts for grounding.
z Check for exhaust manifolds or other
engine component grounding on the
body or frame.
z Is there evidence of grounding on
the body or frame? Yes
REPAIR the components as necessary. TEST the
system for normal operation.
No
GO to
E2 .
E2 CHECK FOR ACCESSORY DRIVE
VIBRATIONS z
Key in START position.
z Remove the accessory drive belt.
z Does the vibration stop when the
accessory drive belt is removed
from the engine? Yes
REFER to
Section 303 - 05 to diagnose the
accessory drive belt components.
No
STOP the engine and INSTALL the drive belt. GO
to E3 .
E3 CHECK FOR RELEASE BEARING
NOISE z
Key in START position.
z Depress and hold the clutch pedal.
z Is a whirring, grating, or grinding
noise present only when pedal is
pushed? Yes
INSTALL a new clutch release hub and bearing.
REFER to
Section 308 - 01 .
No
GO to E4 .
E4 INSPECT THE FLYWHEEL
z
Key in OFF position.
z Remove the transmission. Refer to
Section 308 - 03A or
Section 308 - 03B .
z Carry out a flywheel check. Refer to
Flywheel Runout Check . Yes
VERIFY customer concern. GO to
Symptom Chart if necessary.
No Klj . 10 ba
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stopped and the measurement taken at the downstop is the
clutch reserve.
z Is the clutch reserve less than 19 mm (0.75 inch)? Item Pedal Position
1 Gear clash begins
2 Gear clash ends
3 Clutch pedal downstop
F5 INSPECT THE RELEASE LEVER AND PIVOT STUD
z
Remove the transmission.
z Inspect the release lever and the pivot stud for wear,
damage or misalignment.
z Is the release lever or pivot stud worn, damaged or
misaligned? Yes
INSTALL a new release
lever or pivot stud as
necessary. TEST the
system for normal
operation.
No
GO to
F6 .
F6 INSPECT THE RELEASE BEARING
z
Inspect the release bearing for wear or damage. Make sure
the release lever is seated in the release bearing pocket.
z Is the release bearing worn or damaged? Yes
INSTALL a new release
bearing. TEST the system
for normal operation.
No
GO to
F7 .
F7 INSPECT THE PILOT BEARING
z
Inspect the pilot bearing for wear or damage.
z Is the pilot bearing worn or damaged? Yes
INSTALL a new pilot
bearing. TEST the system
for normal operation.
No
GO to
F8 .
F8 INSPECT THE CLUTCH PRESSURE PLATE TO FLYWHEEL
BOLTS z
Measure the clutch pressure plate to flywheel bolts.
z Is the bolt torque greater than or equal to 65 Nm (48 lb-
ft)? Yes
INSTALL a new pressure
plate and clutch disc. Note
the condition of the
removed components
(wear, damage or oil
contamination). For oil Klj . 13 ba
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DESCRIPTION AND OPERATION
Body Sealer Types And Applications
Liquid Butyl Sealer
HB Fuller E709-19554-
B or equivalent meeting Ford Specification ESB-M4G162- A:
z Does not run.
z Is fast drying.
z Remains semi-elastic.
z Can be used for seam sealing on the floorpan, wheelhouse, body rocker panels, door openings,
and drip rails.
Caulking Cord
3M Strip Caulk- Black 051135-08578 or equivalent meeting Ford specification ESB-M4G32- A:
z Is a heavy- bodied, plastic base with a filler.
z Is commonly known as perma-gum.
z Is used on spot- welds holes, around moulding clips, and between surfaces not sealed with a
gasket.
Weatherstrip Adhesive
Weatherstrip and Rubber Adhesive E8AZ-19552- A or equivalent meeting Ford specification ESB-
M2G14- A:
z Is a quick drying, strong adhesive designed to hold weatherstripping onto all body panels and
surrounding metal.
Silicone Lubricant
Silicone Lubricant C0AZ-19553-AA meeting Ford specification ESR- M13P4-A:
z Is used to keep the door and the window weatherstrip pliable and soft.
z Should be applied to the weatherstrip at every lubrication period.
z Makes the door easier to close.
z Retards weatherstrip squeaks.
z Retards weatherstrip wear.
z Helps retain door window alignment by reducing friction between the glass frame and the rubber
weatherstrip.
z Should not be used prior to painting.
SECTION 501-
00: Body System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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