2003 FORD MUSTANG parking brake

DIAGNOSIS AND TESTING
Starting System
Refer to Wiring Diagrams Cell
20 , Starting System for schematic and connector information.
Inspection and Verification WARNING: When servicing starter motor or carrying out other underhood work in the
vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter
solenoid is "electrically hot" at all times. A protective cap or boot is provided over this terminal
that must be installed after servicing. Be sure to disconnect the battery negative cable before
servicing the starter. Failure to follow these instructions may result in personal injury.
WARNING: When working in area of the starter motor, be careful to avoid touching hot
exhaust components. Failure to follow these instructions may result in personal injury.
WARNING: When using a remote starter switch or jumper wire, be sure the ignition switch
is in the OFF position and the transmission is in PARK (A/T) or Neutral (M/T) with the parking
brake control fully applied.
1. Verify the customers concern by operating the starting system to duplicate the conditions.
2. Inspect to determine if any of the following mechanical or electrical concerns apply.
3. If the inspection reveals an obvious concern that can be readily identified, repair as necessary.
4. If the concern remains after the inspection, determine the symptom. GO to Symptom Chart .
SECTION 303-
06: Starting System 2003 Mustang Workshop Manual Special Tool(s)
Digital Multimeter
105-
R0051 or equivalent Visual Inspection Chart
Mechanical Electrical
z
Starter motor
z Brackets z
Battery
z Battery junction box (BJB) fuse ignition switch (40A)
z Central junction box (CJB) Fuse 6 (20A)
z Fuse 24 (10A)
z Damaged wiring harness
z Starter Relay
z Loose or corroded connections Klj . 1 ba
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Component Tests
Starter Motor —Voltage Drop Test
WARNING: When servicing starter motor or carrying out other underhood work in the
vicinity of the starter motor, be aware that the heavy gauge battery input lead at the starter
solenoid is "electrically hot" at all times. A protective cap or boot is provided over this terminal
that must be installed after servicing. Be sure to disconnect the battery negative cable before
servicing the starter. Failure to follow these instructions may result in personal injury.
WARNING: When using a remote starter switch or jumper wire, be sure the ignition switch
is in the OFF position and the transmission is in PARK (A/T) or Neutral (M/T) with the parking
brake control fully applied.
Always make the Digital Multimeter connections at the component terminal rather than at the wiring
end connector. Making a connection at the wiring end connector could result in false readings because
the meter will not pick up a high resistance between the wiring connector and the component.
Starter Motor— Motor Feed Circuit
1. Make sure the battery is fully charged. Perform a battery load test. For additional information, refer to Section 414 - 00 .
2. Disconnect the inertia fuel shut off (IFS) switch.
3. Connect a remote starter switch between the starter solenoid S- terminal and the battery positive
(+) terminal.
4. Connect the Digital Multimeter positive lead to the battery positive (+) post. Connect negative lead to the starter solenoid M- terminal. brackets for cracks.
z Check the starter motor mounting
bolts for looseness.
z Is the starter motor mounted
correctly? GO to
D2 .
No
REINSTALL the starter motor correctly. REFER to
Starter Motor — 3.8L or
Starter Motor — 4.6L in this
section. D2 INSPECT THE STARTER MOTOR
z
Remove the starter motor; refer to
Starter Motor — 3.8L or
Starter Motor — 4.6L in this section.
z Inspect the starter motor for
damage.
z Is the starter motor damaged? Yes
INSTALL a new starter motor. REFER to
Starter Motor — 3.8L or
Starter Motor — 4.6L in this section.
TEST the system for normal operation.
No
CHECK the starter drive. REFER to Component
Tests, Starter Drive Test in this section. INSTALL a
new starter motor. TEST the system for normal
operation. Klj . 8 ba
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C1 VERIFY DIAGNOSTIC TROUBLE CODES
z
Select PARK.
z Key in OFF position.
z NOTE: DTC codes P0705 and P0708 cannot be set by
an incorrectly adjusted digital TR sensor.
z Carry out on board diagnostic test.
z Are only DTC codes P0705, P0708 present? Yes
GO to
C4 .
No
GO to C2 .
C2 VERIFY DIGITAL TRANSMISSION RANGE SENSOR
ALIGNMENT z
Check to make sure the digital TR sensor harness
connector is fully seated, pins are fully engaged in
connector and in good condition before proceeding.
z Apply the parking brake.
z Select NEUTRAL.
z Disconnect the shift cable/linkage from the manual lever.
z Verify that the digital TR Sensor Alignment Tool fits in
the appropriate slots.
z Is the digital TR sensor adjustment OK? Yes
GO to
C3 .
No
ADJUST the digital TR sensor.
PLACE transmission range
selector lever in P and CLEAR
DTCs. REPEAT OBD Tests.GO
to C3 .
C3 VERIFY SHIFT CABLE/LINKAGE ADJUSTMENT
z
Place the manual lever in the overdrive position.
z Select DRIVE.
z Reconnect the shift cable/linkage.
z Verify that the shift cable/linkage is adjusted OK. Refer
to Section 307 - 05 .
z Is the shift cable/linkage adjusted OK? Yes
GO to
C4 .
No
ADJUST the shift cable/linkage.
REFER to Section 307 - 05 .
C4 CHECK ELECTRICAL SIGNAL OPERATION
z
Select PARK.
z Disconnect: Digital TR Sensor.
z CAUTION: Do not pry on connector. This will
damage the connector and result in a transmission
concern.
z Press the button and pull out on the digital TR harness
connector.
z Inspect both ends of the connector for damage or
pushed- out pins, corrosion, loose wires and missing or
damaged seals.
z Are the connector, pins and harness damaged? Yes
REPAIR as required. CLEAR
DTCs and REPEAT OBD
Tests.
No
If diagnosing a DTC, GO to
C5
.
If diagnosing a starting concern
or a reversing lamp concern,
GO to C10 .
C5 CHECK ELECTRICAL SYSTEM OPERATION (DIGITAL
TR AND PCM) z
Key in OFF position.
z Connect the diagnostic tool.
z Connect: Digital TR Sensor.
z Key in ON position.
z Enter the following diagnostic mode on the diagnostic
tool: TR PIDS TR, TR_D, TR_V.
z Move transmission range selector lever into each gear
and stop.
z Observe any of the following PIDs, TR and TR_D, TR_V
(vehicle dependent) while wiggling harness, tapping on
sensor, or driving the vehicle. Use PIDs TR, and TR_D
for DTCs P0705, P1704, and P1705. Use PIDs TR, and
TR_V for DTC P0708.
z Compare the PIDs to the Digital Transmission Range
(TR) Sensor Diagnosis Chart.
z Do the PIDs TR, TR_D and TR_V match the Digital
Transmission Range (TR) Sensor Diagnosis chart,
and does the TR_D PID remain steady when the Yes
The problem is not in the digital
TR sensor system. REFER to
Diagnosis By Symptom
in this
section for further diagnosis.
No
If TR_D changes when wiggling
harness, tapping on the sensor,
or driving the vehicle, the
problem may be intermittent.
GO to C6 . Klj . 10 ba
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Stall Speed Test
WARNING: Apply the parking brake firmly while carrying out each stall test.
CAUTION: Carry out line pressure test prior to carrying out stall test. If the line pressure is
low at stall, do not carry out stall test or further transmission damage will occur.
The stall speed test checks:
zthe torque converter clutch operation and installation.
z the holding ability of the forward clutch.
z the reverse clutch (the low- reverse bands).
z the planetary one- way clutch.
z the engine driveability.
Conduct this test with the engine coolant and transmission fluid at correct levels and at normal
operating temperature.
Apply the parking brake firmly for each stall speed test. 1. Find the specified stall rpm for the vehicle; see the stall speed diagnosis chart. Use a grease pencil to mark the rpm on the dial of a tachometer.
2. Connect a tachometer to the engine.
3. NOTE: If the rpm recorded by the tachometer exceeds the maximum limits, release the
accelerator pedal immediately because clutch or band slippage is indicated.
In each of the following ranges (D), 2, 1, R, press the accelerator pedal to the floor and hold it ·
Reverse Clutch Low In Neutral Only ·
Valve Body Low In Overdrive Only ·
Forward Clutch ·
Valve Body Low In 1st Position Only ·
Forward Clutch ·
Valve Body ·
Low/Reverse Servo Low In 2nd Only ·
Intermediate Clutch ·
Valve Bodies ·
Forward Clutch Stall Speed
Application Min. Max.
3.8L engine 2,240 2,619
4.6L 2V engine 2,339 2,738
4.6L 4V MACH 1 engine 2,375 2,767 Klj . 4 ba
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Shift Linkage, Digital TR Sensor
·
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. Park Mechanism
·
Output shaft ring, parking brake pawl,
parking pawl return spring, park rod
guide cup, parking pawl shaft,
parking pawl actuating rod, manual
lever detent spring damaged or
assembled incorrectly ·
Inspect for damage or incorrect assembly and repair as
required.
Other Concerns: Overheating Possible Component Reference/Action
257 —
ELECTRICAL ROUTINE Refer to Routine 240/340, Torque Converter Operation Concern: No Apply
357 —
HYDRAULIC/MECHANICAL ROUTINE Fluid
·
Incorrect level ·
Adjust fluid to correct level. ·
Condition ·
Inspect condition of fluid. Other
·
Damaged, blocked or reversed cooler lines or
restriction in the transmission oil cooler ·
Inspect for damage and correct
installation. Repair as required. Vehicle Concerns Causing Engine Overheating
·
Refer to the appropriate engine
cooling section. Main Controls
·
Drain back valve, torque clutch control valve, converter
limit valve stuck, damaged or assembled incorrectly ·
Inspect for damage and repair as
required. Torque Converter Clutch
·
No apply ·
Refer to Routine 240/340. Klj . 30 ba
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Pinpoint Tests
PINPOINT TEST A: CLUTCH SLIPPAGE
PINPOINT TEST B: CLUTCH CHATTER OR SHUDDER z
Shafts or bore.
z Overloading of
vehicle.
z Incorrect
preload.
z Input shaft oil
dam. z
Install new components
as necessary and verify
the oil dam installation is
correct. REFER to
Section 308 - 03A or
Section 308 - 03B .
CHECK for correct
installation of the snap
ring on the mainshaft
next to the oil dam.
z Oil baffle in the
input bearing
shim pack. z
INSTALL a new oil
baffle, making sure it is
not damaged during
assembly. REFER to
Section 308 - 03A or
Section 308 - 03B .
Test Step Result / Action to Take
A1 INSPECT THE CLUTCH LINKAGE
z
Key in OFF position.
z Block the wheels and apply the parking brake.
z Depress and slowly release the clutch pedal.
z Does the clutch pedal release without
binding? Yes
GO to
A2 .
No
INSPECT the clutch pedal. REFER to
Section 308 - 02 .
A2 CARRY OUT A STALL TEST
z
Key in START position.
z Block the wheels and apply the parking brake.
z Place the transmission in fourth gear.
z Increase the engine speed to 2000 rpm and
slowly release the clutch pedal.
z Does the engine stall within five seconds? Yes
The clutch is not slipping. VERIFY the
customer concern.
No
INSPECT the clutch components for
damage.
Test Step Result / Action to Take
B1 CHECK ENGINE OR TRANSMISSION MOUNTS
z
Inspect all the engine and transmission mounts
for looseness or damage. Refer to Section 303 -
01A or
Section 303 - 01B and
Section 308 - 03A or
Section 308 - 03B .
z Are any of the engine or transmission mounts Yes
TIGHTEN or INSTALL new engine
mounts or transmission mounts. TEST
the system for normal operation. Klj . 7 ba
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PINPOINT TEST C: CLUTCH DRAG loose or damaged? No
GO to
B2 .
B2 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 B3 .
B3 INSPECT PRESSURE PLATE
z
Remove the clutch pressure plate. Refer to
Section 308 - 01 .
z Inspect the clutch pressure plate. Refer to
Pressure Plate Check .
z Are 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 B4 .
B4 CHECK CLUTCH DISC
z
Carry out the clutch disc inspection procedure.
Refer to Disc Check .
z Is the clutch disc OK? Yes
GO to
B5 .
No
INSTALL a new clutch disc. REFER to
Section 308 - 01 . TEST the system for
normal operation. B5 INSPECT THE FLYWHEEL
z
Inspect the flywheel for damage and runout. Refer
to Flywheel Runout Check .
z Is the flywheel OK? Yes
GO to
B6 .
No
REPAIR or INSTALL a new flywheel
as necessary. REFER to Section 308 -
01 . TEST the system for normal
operation. B6 INSPECT THE INPUT SHAFT
z
INSPECT the input shaft for signs of wear or
damage.
z Are any signs of wear or damage present on
the input shaft? Yes
INSTALL a new input shaft. REFER to
Section 308
- 03A or
Section 308 - 03B .
No
VERIFY the customer concerns. GO
to Symptom Chart if necessary.
Test Step Result / Action to Take
C1 CHECK HIGH SHIFTING EFFORTS
z
Key in START position.
z Set parking brake.
z With the shift control selector in REVERSE, Yes
Clutch system OK.
No Klj . 8 ba
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GENERAL PROCEDURES
Air Conditioning (A/C) System Check —
Retail Procedure
NOTE: This Retail Procedure is not eligible for claiming on Ford paid repairs (warranty and ESP).
NOTE: The engine should be run at idle for 10 minutes with the air conditioning on and set to MAX A/C
before carrying out this retail procedure.
NOTE: Read and follow all of the Warnings, Cautions and Notes at the beginning of this section before
continuing.
1. Visual inspection
Open the hood and visually inspect the heating and air conditioning systems for the following:
zCoolant reservoir for correct coolant level
z Heater hoses for deterioration or loose connections
z Radiator and condenser for debris or damaged fins restricting airflow, loose mounting or
connections
z Accessory drive belt(s) and cooling fan(s) for wear or physical damage
z Refrigerant lines and connections for physical damage or loose connections
z Compressor for physical damage or loose connections
z Suction accumulator/drier for physical damage or loose connections
z Wiring and connectors for excessive wear, loose or damaged connections, or incorrect
routing
2. A/C refrigerant analysis
zCarry out air conditioning refrigerant analysis. For additional information, refer to
Refrigerant Identification Testing in this section.
z If the refrigerant fails the analysis, discontinue diagnosis and make recommendations for
repairs.
z If the refrigerant passes the analysis, carry out the air conditioning system check.
3. Air conditioning system check
zConnect manifold gauge set or charging station with gauges to refrigerant system.
z With the vehicle in park, parking brake set, thermometer installed in center panel vent,
and air conditioning system on and set to MAX A/C, start the engine.
z Record air refrigerant system pressures while running the engine at 1,500 rpm and allow
engine to return to idle.
z Operate the blower motor in all control positions and check for correct blower speed
changes.
z With the blower motor on HI, operate air discharge mode selector in all positions and
check for correct airflow in each position.
z Operate the temperature blend selector in all positions and check for correct change in
discharge temperature. Check the air discharge temperature with the selector in the
coolest position and the air conditioning on and set to MAX A/C to determine if the air
discharge temperature is acceptable for the current ambient air temperature.
z Carry out the EATC self- test (if applicable).
If the refrigerant system pressures were low, carry out the refrigerant system leak test.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Klj . 1 ba
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