2003 FORD MUSTANG steering wheel

For low or spongy brake pedal concerns:
zcheck and, if necessary, refill the brake master cylinder reservoir.
z bleed the brake system and retest the brake pedal feel.
z if the brake pedal is still low or feels spongy, check the brake pedal mounting for looseness and
correct installation. Check the power brake booster and the brake master cylinder for loose
mounting. Correct as necessary and retest the system for normal operation.
For a slow or incomplete brake pedal return concern:
zinspect for binding, damage, correct installation or interference at the brake pedal.
z check the power brake booster for binding, damage and correct installation.
Vibration When Brakes are Applied
For vibration concerns when brakes are applied, perform the following procedure.
Visually inspect: ztire condition and pressure.
z suspension bushings and ball joints.
Correct as necessary. 1. Verify and isolate the concern. Brake roughness can be felt in: zthe steering wheel.
z the seat.
z the brake pedal.
2. After verifying the concern, check for related concerns in the: zOn- Line Automotive Service Information System (OASIS).
z Technical Service Bulletins.
3. Check wheel bearing end- play and correct as necessary.
4. NOTE: Begin at the front of the vehicle unless the vibration has been isolated to the rear.
Remove the tire and wheel.
5. Remove the brake caliper.
6. Measure and record the brake disc thickness. Install a new brake disc if the thickness after machining will be at or below specification. The specification is molded into the brake disc. Do z
Power brake booster
z Brake pedal linkage
z Vacuum booster hose
z Tires
z Foreign material Klj . 3 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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Component Tests
Brake Booster
1. Check the hydraulic brake system for leaks or insufficient fluid.
2. With the transmission (7003) in NEUTRAL, stop the engine (6007) and apply the parking brake control (2780). Apply the brake pedal several times to exhaust all vacuum in the system.
3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no
motion is felt, the power brake booster system is not functioning. Continue with the following
steps.
4. Remove the vacuum booster hose from the check valve connection. Manifold vacuum must be available at the check valve end of the vacuum booster hose with the engine at idle speed and
the transmission in NEUTRAL. If the manifold vacuum is available to the power brake booster,
connect the vacuum booster hose to the power brake booster check valve and repeat Steps 2
and 3.
5. If no downward movement of the brake pedal is felt, install a new power brake booster.
6. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10 minutes. Then apply the brake pedal with approximately 89 N (20 lb) of force. The
brake pedal feel should be the same as that noted with the engine operating. If the brake pedal
feels hard (no power assist), install a new power brake booster check valve and retest. If the
brake pedal feels spongy, bleed the hydraulic system to remove air. For additional information,
refer to Bleeding — System in this section. Check Valve z
Engine running at idle speed.
z CAUTION: Do not hold the brake pedal at 444 Nm
(100 lb) force for more than 5 seconds at a time.
z Apply brake pedal with approximately 444 Nm (100 lb)
force and hold.
z Check hydro-boost unit input seal, housing seal,
accumulator seal, piston seal and spool plug seal for
leakage.
z Is hydro- boost unit free of leaks? Yes
GO to
G6 .
No
INSTALL a new hydro- boost
unit. G6 CHECK RESERVE RETENTION
z
Engine running at idle speed.
z CAUTION: Do not hold the brake pedal at 444 Nm
(100 lb) force for more than 5 seconds at a time.
z Charge system to pressure by holding the steering wheel at
stop or by pressing the brake pedal with approximately 444
Nm (100 lb) force.
z Key in OFF position.
z Wait five seconds.
z Press brake pedal and observe if there is any power brake
reserve.
z Is there any power brake reserve? Yes
Hydro-
boost unit is OK.
No
INSTALL a new hydro- boost
unit. Klj . 13 ba
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GENERAL PROCEDURES
Hydro-
Boost Bleeding
1. NOTE: The Hydro- Boost power brake booster (2B560) is generally self- bleeding, and the
following procedure will normally bleed the air from the power brake booster. Normal operation
of the vehicle will further remove any additional trapped air.
Fill the power steering oil reservoir (3A697) with MERCON® Multi- Purpose ATF XT-2-QDX or
MERCON® equivalent.
2. Remove the powertrain control module (PCM) fuse to prevent the engine from starting.
3. Crank the engine for several seconds.
4. Check the fluid level in the power steering oil reservoir and add if necessary. Install the powertrain control module (PCM) fuse.
5. Start the engine.
6. With the engine running, turn the steering wheel (3600) from stop- to-stop twice. Turn the engine
off.
7. Depress the brake pedal (2455) several times to discharge the accumulator.
8. Repeat Steps 5 and 6.
9. If foaming occurs, stop the engine and allow the foam to dissipate.
10. Repeat Steps 5 and 6 as required, until all the air is removed from the system (when the foaming stops).
SECTION 206-
07: Power Brake Actuation 2003 Mustang Workshop Manual Klj . 1 ba
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For information on the power steering oil reservoir (3A697), refer to
Section 211 - 02 .
For information on the steering wheel and column assembly, refer to Section 211 - 04 .
For information on the power steering hoses, refer to Section 211 - 02 .
For information on the front wheel spindles, refer to Section 204 - 01 .
For information on the power steering fluid cooler, refer to Section 211 - 02 .
For information on the power steering pump, refer to Section 211 - 02 .
For information on the steering gear, refer to Section 211 - 02 . Item Part Number Description
1 3A713 Power steering hose
2 3R700 Power steering pump reservoir
3 3A714 Power steering hose
4 2B559 Hydro-boost assy
5 3E525 Power steering hose
6 3504 Steering gear
7 3A130 Tie-
rod end 8 3A713 Power steering hose
9 3D746 Power steering fluid cooler
10 3A674 Power steering pump Klj . 2 ba
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DIAGNOSIS AND TESTING
Steering System
Inspection and Verification
CAUTION: Do not hold the steering wheel (3600) at the stops for an extended amount of
time. Damage to the power steering pump (3A674) will result. NOTE: Make the following preliminary checks before repairing the steering system:
SECTION 211-
00: Steering System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Dial Thermometer 0-
220°F
023- R0007 or Equivalent Hand Held Automotive Meter
105-
R0053 or Equivalent Power Steering Analyzer
211-
F001 (014- 00207) or
Equivalent Spring Scale
211-
034 (T74P-3504- Y) Tach Adapter
418-
F102 (007- 00061) or
Equivalent Tie-
Rod End Remover Tool
211- 001 (TOOL- 3290-D) or
Equivalent Klj . 1 ba
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1. Verify the customer concern by operating the steering system.
2. Inspect Tires
zCheck the tire pressure. Refer to the Vehicle Certification (VC) label.
z Verify that all tires are sized to specification.
z Check the tires for damage or uneven wear.
3. Belt and Tensioner Check zRefer to Section 303 - 05 for diagnosis and testing of the accessory drive system.
4. Fluid Level Check zVerify that the power steering fluid level is within the appropriate indicated range, hot for
the 3.8L engine and cold for the 4.6L engine. Add Motorcraft MERCON® Multi- Purpose
ATF XT -2-QDX or MERCON® equivalent.
5. Air Bleeding zVerify that there is no air in the power steering system. Run the engine (6007) until it
reaches normal operating temperature. Turn the steering wheel to the left and right
several times without hitting the stops. If any air bubbles are present, refer to Purging —
CII Power Steering Pump or
Purging — CIII Power Steering Pump in this section.
External Leak Check — Typical Power Rack-and-Pinion Steering Gear Klj . 2 ba
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6. External Leak Check
zWith the ignition switch at OFF, wipe off the power steering pump, power steering hoses,
power steering fluid cooler (3D746) and steering gear (3504).
z With the engine running, turn the steering wheel from stop- to-stop several times. Do not
hold steering wheel at stops. Check for leaks. Repair as necessary if leaks are observed.
7. Turning Effort Check zRefer to Turning Effort Test under Component Tests in this section.
8. Visually inspect for obvious signs of mechanical damage; refer to the following chart. Klj . 3 ba
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