2003 FORD MUSTANG manual transmission

PINPOINT TEST D: CLUTCH PEDAL PULSATION clutch disengaged and engine idling, move
the shift lever to a position halfway between
REVERSE and NEUTRAL.
z Slowly engage clutch. The transmission will
behave as if it is in NEUTRAL.
z Gear clash can now be heard if an attempt
is made to shift into REVERSE with the
clutch engaged. Reserve can now be
measured.
z While maintaining light pressure on the shift
selector, slowly press the clutch pedal to the
floor. The gear clash will stop and the shift
selector will slide into the REVERSE
position.
z Is there a minimum 19.05 mm (0.750 inch)
clutch pedal reserve? CHECK the clutch pressure plate and clutch
disc. INSTALL a new clutch pressure plate
or clutch disc if necessary. REFER to
Section 308
- 01 . TEST the system for
normal operation. Test Step Result / Action to Take
D1 CHECK THE CLUTCH PEDAL
PULSATION z
Key in START position.
z With the transmission in NEUTRAL,
slowly press the clutch pedal.
z Does the clutch pedal pulsate while
being pressed? Yes
GO to
D2 .
No
VERIFY customer concern. GO to Symptom Chart if necessary.
D2 INSPECT PRESSURE PLATE BOLTS
z
Inspect the pressure plate- to-flywheel
bolts.
z Are any of the pressure plate- to-
flywheel bolts loose? Yes
TIGHTEN or INSTALL new bolts. REFER to
Section 308
- 01 . TEST the system for normal
operation.
No
GO to D3 .
D3 INSPECT THE CLUTCH PRESSURE
PLATE z
Remove the clutch pressure plate.
Refer to Section 308 - 01 .
z INSPECT the clutch pressure plate for
damage. Refer to Pressure Plate Check .
z Are there any signs of damage
present on the clutch pressure plate? Yes
INSTALL a new clutch pressure plate. REFER
to
Section 308 - 01 . TEST the system for normal
operation.
No
GO to D4 .
D4 INSPECT THE CLUTCH DISC
z
Carry out the clutch disc inspection
procedure. Refer to Disc Check .
z Is the clutch disc OK? Yes
GO to
D5 .
No
INSTALL a new clutch disc. REFER to Section 308 - 01 . TEST the system for normal operation.
D5 INSPECT THE FLYWHEEL Klj . 9 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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PINPOINT TEST F: HARD SHIFTING z
Is the flywheel OK? TIGHTEN, RESURFACE or INSTALL a new
flywheel. REFER to
Section 308 - 01 . TEST the
system for normal operation. Test Step Result / Action to Take
F1 CHECK THE CLUTCH RELEASE CABLE
z
NOTE: Check the upper shift boot for twisting.
z NOTE: Check the engine idle speed.
z Inspect the clutch release cable for wear or damage. Make
sure the clutch release cable is correctly routed and that all
the fasteners are installed.
z Are there any fasteners missing or is the cable worn,
damaged or incorrectly routed? Yes
REPAIR or INSTALL a new
clutch release cable as
necessary. TEST the
system for normal
operation.
No
GO to
F2 .
F2 CHECK THE CLUTCH PEDAL
z
Loosen the clutch pedal shaft nut.
z Lift the clutch pedal to the most upward position.
z While holding the clutch pedal in the most upward position,
tighten the nut.
z Was the clutch pedal incorrectly adjusted? Yes
VERIFY customer concern.
TEST the system for
normal operation.
No
GO to
F3 .
F3 CHECK THE CLUTCH PEDAL QUADRANT
z
Pull up on the clutch pedal to the upstop. Pulling up on the
pedal ensures that the quadrant is free to rotate through it's
complete range of motion against the spring load of the
quadrant.
z Is the clutch pedal quadrant binding? Yes
INSTALL a new quadrant.
TEST the system for
normal operation.
No
GO to
F4 .
F4 MEASURE THE CLUTCH RESERVE
NOTE:
Do not check the clutch system after the road test.
Allow the vehicle to cool down before carrying out the clutch
reserve check. NOTE: Remove the floor mat, if equipped, to
allow the clutch pedal to travel to the downstop.
z Install a cable tie to the lower clutch pedal, than attach a
tape measure to the cable tie. Yes
INSTALL a new pressure
plate and clutch disc.
REINSTALL the
transmission. RECHECK
the clutch reserve. TEST
the system of normal
operation.
No
GO to
F5 . Klj . 11 ba
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z
Pull the tape measure up to the steering wheel. Position it
through the steering wheel opening.
z Depress the clutch fully and start the vehicle.
z Shift the transmission into reverse gear, then move the shift
lever forward to the position in between reverse gear and
neutral. Slowly release the clutch pedal (if the vehicle creeps
rearward, move the shift lever forward a little more). The
transmission will behave as if in neutral, but the reverse gear
synchronizer will be bypassed.
z With the clutch pedal up, gently pull the shift lever toward the
reverse gear position. Gear clash can now be heard.
z Slowly depress the clutch pedal. Using the steering wheel
inner seam as a reference, note the measurement when the
gear clash stops or the shift lever slides into reverse gear.
Depress the clutch pedal to the downstop. The difference
between the measurement taken when the gear clash Klj . 12 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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PINPOINT TEST G: EXCESSIVE NOISE contamination, REPAIR as
necessary. TEST the
system for normal
operation. If the
transmission is still hard to
shift, GO to
F9 .
No
TIGHTEN the bolts to 80
Nm (59 lb- ft). TEST the
system for normal
operation. If the
transmission is still hard to
shift, GO to F9 .
F9 INSPECT THE TRANSMISSION
z
Remove the transmission.
z Disassemble the transmission. Refer to Section 308 - 03B .
z Carry out the following:
zinspect all the shift rails for excessive scuffing or
wear.
z check the interlock pins on the shift rail.
z make sure the interlock bolts are tighten to 31 Nm (23
lb-ft).
z inspect the shift pads for wear or cracking.
z inspect the shift forks for wear or damage.
z check the synchronizer rings (of the affected gear[s])
for wear or damage.
z check the synchronizer hubs (of the affected gear[s])
for wear or damage.
z inspect the clutching teeth of the affected gear.
z Are there any internal components worn or damaged? Yes
INSTALL new components
or REPAIR as necessary.
TEST the system for
normal operation.
No
ASSEMBLE and INSTALL
the transmission. TEST the
system for normal
operation.
Test Step Result / Action to Take
G1 TRANSMISSION NEUTRAL GEAR ROLLOVER TEST
z
Start the engine and let it idle with the transmission in
neutral and the clutch engaged (pedal up). If noise is
excessive, depress the clutch pedal to stop the
transmission input shaft from rotating.
z Does the noise stop when the clutch pedal is
depressed? Yes
INSPECT the clutch component
for damage. REFER to General
Procedures in this section.
No
GO to
G2 .
G2 CHECK THE PILOT BEARING
z
Inspect the pilot bearing for damage. Refer to Bearing .
z Is the pilot bearing OK? Yes
GO to
G3 .
No
INSTALL a new pilot bearing.
REFER to Section 308 - 01 .
G3 CHECK TORSION SPRINGS
z
Inspect the torsion springs for fatigue or breakage.
z Are there any signs of fatigue or breakage? Yes
INSTALL a new clutch disc.
REFER to
Section 308 - 01 .
TEST the system for normal
operation. Klj . 14 ba
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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
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GENERAL PROCEDURES
Pressure Plate Check
1. Check the clutch pressure plate surface for scoring, cracks or discoloration. Minor scratches or discoloration should be removed with a fine emery cloth.
2. Measure the flatness of the clutch pressure plate surface with a straightedge and a feeler gauge.
3. Check the diaphragm spring fingers for discoloration, scoring, bent or broken segments and spring ends that are higher or lower than the rest.
4. Measure the wear of the diaphragm spring fingers.
SECTION 308-
00: Manual Transaxle/Transmission and Clutch — General
Information 2003 Mustang Workshop
Manual Klj . 1 ba
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