2003 FORD MUSTANG drain bolt

Fluid Leakage in Torque Converter Area
In diagnosing and correcting fluid leaks in the front pump support and gear and torque converter area,
use the following procedures to locate the exact cause of the leakage. Leakage at the front of
transmission, as evidenced by fluid around the torque converter housing, may have several sources.
By careful observation it is possible, in many instances, to pinpoint the source of leak before removing
the transmission from the vehicle. The paths which the fluid takes to reach the bottom of the torque
converter housing are shown in the illustration. The five steps following correspond with the numbers
in the illustration.
1. Fluid leaking by the front pump seal lip will tend to move along the impeller hub and onto the back of the impeller housing. Except in the case of a total seal failure, fluid leakage by the lip of
the seal will be deposited on the inside of the torque converter housing only, near the outside
diameter of the housing.
2. Fluid leakage by the outside diameter of the front pump seal and front pump body will follow the same path that leaks by the inside diameter of the front pump seal follow.
3. Fluid that leaks by a front pump to case bolt or pump gasket will be deposited on the inside of the torque converter housing only. Fluid will not be deposited on the back of the torque
converter.
4. Fluid leakage from the converter drain plug, (model dependent) converter seal weld or converter to flexplate stud weld will appear at the outside diameter of the torque converter on the back
face of the flexplate and in the converter housing only near the flexplate. Fluid leaks from the
torque converter will leave a ring of fluid around the inside of the torque converter housing.
5. NOTE: White facial tissue paper may aid in determining the color (red is transmission fluid) and
source of the leaking fluid.
Engine oil leaks are sometimes incorrectly diagnosed as transmission pump gasket leaks. The 22 7D273 Fluid tube connector
23 87650-S2 Converter drain plug Klj . 3 ba
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Pump
·
Gaskets damaged ·
Inspect for damage and install a new gasket. ·
Porosity/cross leaks ·
Inspect for leak/porosity. Install a new pump as required. Intermediate Clutch Assembly
·
Piston damaged ·
Inspect for damage. Repair as required. ·
Friction elements damaged,
worn ·
Inspect for damage. Repair as required. ·
End clearance incorrect ·
Inspect and correct; refer to Transmission Assembly. Intermediate One-
Way Clutch ·
Damaged ·
Inspect for damage. Repair as required. ·
Intermediate one- way clutch
retaining snap ring not seated ·
Inspect for damage. Repair as required. Planetary One-
Way Clutch ·
Not holding or damaged ·
Inspect for damage. Repair as required.
Torque Converter Clutch Operation Concerns: No Apply Possible Component Reference/Action
240 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, torque
converter clutch (TCC) solenoid, TFT
sensor, OSS ·
Carry out Self- Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for
diagnosis and testing of the Powertrain Control System.
Go To Pinpoint Test B or
Go To Pinpoint Test E .
Repair as required. Clear codes, road test and repeat
Self- Test. 340 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage
·
Damaged or incorrectly adjusted ·
Inspect and repair as required. Verify transmission shift
cable adjustment; refer to Section 307 - 05 . Adjust
transmission shift cable as necessary. After repairing
transmission shift cable, verify that the digital TR
sensor is correctly adjusted. Adjust the digital TR
sensor as necessary. Incorrect Pressures
·
Low line pressure, low EPC pressure ·
Check pressure at line and EPC taps; refer to Line
Pressure Chart for specifications. If pressure is low,
check EPC and main regulator valve. If within
specifications, check the main controls. Main Controls
·
Solenoid pressure regulator valve,
manual valve, bypass clutch control
valve and plunger, converter
pressure limit valve, drain back valve
stuck, damaged or assembled
incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to specifications ·
Tighten bolts to specifications. ·
Solenoid screen blocked or damaged ·
Clean or install a new screen. ·
TCC solenoid malfunction ·
Activate solenoid using scan tool. If solenoid operation Klj . 23 ba
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cannot be felt when placing hand on solenoid, install a
new solenoid. Inspect O- rings for damage. Repair as
required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Pump Assembly
·
Bolts not tightened to specifications ·
Tighten bolts to specifications. ·
Porosity/cross leaks, balls leaking ·
Inspect for porosity/leaks, ball missing. Install a new
pump as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Input Shaft
·
Seals damaged ·
Inspect for damage. Repair as necessary. Torque Converter Assembly
·
Leakage, friction material damaged,
internal seals damaged ·
Inspect torque converter. Repair or install a new or
remanufactured torque converter as required.
Torque Converter Clutch Operation Concerns: Always Applied/Stalls Vehicle Possible Component Reference/Action
241 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs,
vehicle wiring harnesses,
PCM, torque converter clutch
(TCC) solenoid, TFT sensor ·
Carry out Self- Test. Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for diagnosis and testing of the
Powertrain Control System. Go To Pinpoint Test B or
Go To Pinpoint Test A . Repair as required. Clear DTCs, road test
and repeat Self- Test. 341 —
HYDRAULIC/MECHANICAL ROUTINE Main Control
·
Drain back valve, torque
converter clutch (TCC) and
plunger stuck, damaged or
assembled incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
TCC solenoid malfunction ·
Activate solenoid using scan tool. If solenoid operation cannot
be felt when placing hand on solenoid, install a new solenoid.
Inspect O- rings for damage. Repair as required. ·
No. 7 ball incorrect seating ·
Inspect for damage. Repair as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Pump Assembly
·
Bolts not tightened to
specifications ·
Tighten bolts to specifications. ·
Ball missing, leaking,
porosity/cross leaks ·
Inspect for porosity/leaks, balls missing. Install a new pump as
required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Input Shaft
·
Seals damaged ·
Inspect for damage. Repair as required. Torque Converter Assembly Klj . 24 ba
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·
No end clearance ·
Inspect converter and install a new or remanufactured torque
converter as required. ·
Piston plate damaged or stuck
to cover ·
If cover is heat- stained, install a new converter and determine
the cause of the overheat condition.
Torque Converter Clutch Operation Concerns: Cycling/Shudder/Chatter Possible Component Reference/Action
242 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, PCM, torque
converter clutch (TCC) solenoid,
OSS ·
Carry out Self-Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for
diagnosis and testing of the Powertrain Control System.
Go To Pinpoint Test E . Repair as required. Clear
DTCs, road test and repeat Self- Test. ·
Speed control equipped vehicles ·
Evaluate with speed control off. 342 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Condition ·
Inspect fluid condition. If burnt, drain fluid and converter.
Install a new fluid and filter assembly. Bring vehicle to
normal operating temperature. Carry out Transmission
Drive Cycle Test. Carry out Transmission Self- Test. If
condition still exists, continue diagnostics. Main Controls
·
Solenoid pressure regulator valve,
No. 7 check ball, bypass clutch
control valve and plunger, converter
pressure limit valve stuck, damaged
or assembled incorrectly ·
Inspect for damage. Repair as required. ·
Bolts not tightened to specifications ·
Tighten bolts to specifications. ·
Solenoid screen blocked or damaged ·
Clean or install a new screen. ·
TCC solenoid malfunction ·
Activate solenoid using scan tool. If solenoid operation
cannot be felt when placing hand on solenoid, install a
new solenoid. Inspect O- rings for damage. Repair as
required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Pump Assembly
·
Bolts not tightened to specification ·
Tighten bolts to specification. ·
Porosity/cross leaks, missing balls or
leaking ·
Inspect for porosity/leaks or missing balls. Install a new
pump as required. ·
Gaskets damaged ·
Inspect for damage and install a new gasket. Input Shaft
·
Seals damaged ·
Inspect for damage. Repair as required. Torque Converter
·
Excessive end clearance ·
Inspect converter. Install a new or re- manufactured
torque converter as required.
Other Concerns: No Engine Braking In Manual 2nd Or Manual 1st Position Klj . 25 ba
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mechanism damaged
Main Controls
·
Manual valve stuck or
damaged ·
Inspect for damage. Repair as required. ·
Bolts not tightened to
specifications ·
Tighten bolts to specifications.
Other Concerns: External Leaks Possible Component Reference/Action
252 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, sensor
seals leaking (digital TR, OSS,
vehicle speed sensor VSS, if
equipped, or transmission connector) ·
Inspect for leakage and repair as required. 352 —
HYDRAULIC/MECHANICAL ROUTINE Case
·
Case vent, case porosity, case
cracked ·
Check the vent for free breathing. Check the fluid level.
Check the transmission for overheat conditions. Repair
as required. Seals/Gaskets
·
Leakage at gaskets, seals, etc. (refer
to external sealing illustration for
potential leak locations) ·
Remove all traces of lubricant on exposed surfaces of
the transmission. Check the vent for free breathing.
Operate the transmission at normal temperatures and
perform fluid leakage check. Repair as required. Other
·
Cooler fitting, cooler lines pressure
tap, converter drain plug, band
anchor pins ·
Locate the source of the leak. Repair as required.
Other Concerns: Poor Vehicle Performance Possible Component Reference/Action
253 —
ELECTRICAL ROUTINE Powertrain Control System
·
Electrical inputs/outputs, vehicle
wiring harnesses, shift solenoids,
digital TR sensor, torque
converter clutch (TCC) solenoid,
transmission fluid temperature
(TFT) sensor ·
Carry out Self-Test. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual for diagnosis
and testing of the Powertrain Control System. Go To Pinpoint Test A ,
Go To Pinpoint Test B or
Go To Pinpoint Test C . Repair as required. Clear codes, road test and
repeat Self- Test. Also refer to Routines 241/341 Torque
Converter Operation Concern: Always Applied. ·
Engine driveability concerns ·
Inspect air intake/air filter system. Check the fuel system
and fuel pressure. Refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual. Inspect the
exhaust system for restriction. Refer to Section 309 - 00 .
353 —
HYDRAULIC/MECHANICAL ROUTINE Shift Linkage, Digital TR Sensor Klj . 27 ba
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4. Use only clean automatic transmission fluid.
5. Once the fluid exchange has been completed, disconnect the flush and fill machine. Reconnect
any disconnected fluid cooler tubes.
6. With the engine running and the transmission at normal operating temperature 66- 77°C (150-
170°F), check and adjust the transmission fluid level, and check for any leaks. If fluid is needed,
add fluid in increments of 0.24- liter (0.5-pint) until the correct level is achieved (fluid should be in
the cross- hatched area of the fluid level indicator).
Draining
Vehicles equipped with a torque converter drain plug 1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100 - 02 .
2. Loosen the transmission fluid pan bolts and allow the fluid to drain.
3. After the fluid has drained, remove the transmission fluid pan.
4. Do not remove the fluid filter. It is not necessary to change the fluid filter during a normal maintenance fluid change.
5. Remove the torque converter drain plug cover. Klj . 2 ba
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10. Install the torque converter drain plug cover.
11. Position the magnet into the transmission fluid pan.
12.
NOTE: The fluid pan gasket is reusable, clean and inspect for damage. If not damaged, the
gasket should be reused.
Install the fluid pan and gasket. 1. Position the fluid pan with the gasket in place.
2. Install the bolts.
13. CAUTION: The use of any other transmission fluid can result in the transmission
failing to operate in a normal manner or transmission failure.
Fill the transmission.
zAdd 4.7 liters (5 qts) of clean automatic transmission fluid to the transmission through the
fluid filler tube.
14. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements.
15. With the engine running and the transmission at normal operating temperature 66- 77°C (150- Klj . 4 ba
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170°F), check and adjust the transmission fluid level, and check for any leaks. If fluid is needed,
add fluid in increments of 0.24-
liter (0.5-pint) until the correct level is achieved (fluid should be in
the cross- hatched area of the fluid level indicator).
Draining
Vehicles without a torque converter drain plug 1. With the vehicle in NEUTRAL, position on a hoist. For additional information, refer to Section 100 - 02 .
2. Loosen the transmission fluid pan bolts and allow the fluid to drain.
3. After the fluid has drained, remove the transmission fluid pan.
4. Do not remove the fluid filter. It is not necessary to change the fluid filter during a normal maintenance fluid change.
5. Clean and inspect the transmission fluid pan, transmission fluid pan gasket and magnet.
6. Thoroughly flush the cooler tubes. For additional information, refer to Transmission Fluid Cooler — Backflushing and Cleaning in this section. Klj . 5 ba
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