2003 FORD MUSTANG Workshop Manual

change key battery radio ECO mode tires clock hood release

Page 57 of 4378

FORD MUSTANG 2003 Workshop Manual �z
After determining the "system", use the diagnostic tools to identify the worn or damaged
"components".
�z After identifying the "components", try to find the "cause" of the failure.
Once the con

z
After determining the "system", use the diagnostic tools to identify the worn or damaged
"components".
z After identifying the "components", try to find the "cause" of the failure.
Once the concern is narrowed down to a symptom/condition, proceed to NVH Condition and Symptom
Categories.
NVH Condition and Symptom Categories
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal
system. Use the condition and symptom categories as follows:
zIdentify the operating condition that the vehicle is exhibiting.
z Match the operating condition to the symptom.
z Verify the symptom.
z Identify which category or system could cause the symptom.
z Refer to the diagnostic symptom chart that is referred to.
Operating Condition— Vehicle is Not Moving
1. Static operation zNoise occurs during component/system functioning. GO to Symptom Chart — Squeak
and Rattle .
2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart — Engine Noise/Vibration .
2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart —
Squeak and Rattle .
3. Vibration. Acceptable condition.
3. At idle zIdle noise. GO to Symptom Chart — Idle Noise/Vibration .
z Idle vibration or shake. GO to Symptom Chart — Idle Noise/Vibration .
4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise.
2. Vehicle parked on a flat surface. GO to Symptom Chart — Driveline Noise/Vibration .
3. Vehicle with a manual transmission. GO to Symptom Chart — Transmission (Manual)
and Transfer Case Noise/Vibration .
Operating Condition— Vehicle is Moving
1. Depends more on how the vehicle is operated 1. Speed related
„Related to vehicle speed
„Pitch increases with vehicle speed. GO to Symptom Chart — Tire
Noise/Vibration .
„ Noise occurs at specific vehicle speed. A high- pitched noise (whine). GO to
Symptom Chart — Driveline Noise/Vibration . Klj . 10 ba
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FORD MUSTANG 2003 Workshop Manual �„
Loudness proportional to vehicle speed. Low- frequency noise at high
speeds, noise and loudness increase with speed. GO to Symptom Chart —
Driveline Noise/Vibration .
�„ A low- pitched n

„
Loudness proportional to vehicle speed. Low- frequency noise at high
speeds, noise and loudness increase with speed. GO to Symptom Chart —
Driveline Noise/Vibration .
„ A low- pitched noise (drumming). GO to Symptom Chart — Engine
Noise/Vibration .
„ Vibration occurs at a particular speed (mph) regardless of acceleration or
deceleration. GO to Symptom Chart — Tire Noise/Vibration .
„ Noise varies with wind/vehicle speed and direction. GO to Symptom Chart — Air Leak and Wind Noise .
„ Related to engine speed.
„Noise varies with engine rpm. GO to Symptom Chart — Engine
Noise/Vibration .
„ Vibration occurs at a particular speed (mph) regardless of engine speed
(rpm).
2. Acceleration
„Wide open throttle (WOT)
„Engine induced contact between components. Inspect and repair as
necessary.
„ Noise is continuous throughout WOT. Exhaust system or engine ground
out. GO to Symptom Chart — Engine Noise/Vibration .
„ Light/moderate acceleration
„Tip- in moan. Engine/exhaust noise. GO to Symptom Chart — Engine
Noise/Vibration .
„ Knock-type noise. GO to Symptom Chart — Engine Noise/Vibration .
„ Driveline shudder. GO to Symptom Chart — Driveline Noise/Vibration .
„ Engine vibration. GO to Symptom Chart — Engine Noise/Vibration .
3. Turning noise. GO to Symptom Chart — Steering Noise/Vibration .
4. Braking
„Clicking sound is signaling ABS is active. Acceptable ABS sound.
„ A continuous grinding/squeal. GO to Symptom Chart — Brake Noise/Vibration .
„ Brake vibration/shudder. GO to Symptom Chart — Brake Noise/Vibration .
5. Clutching
„A noise occurring during clutch operation. GO to Symptom Chart — Transmission
(Manual) and Transfer Case Noise/Vibration .
„ Vibration. GO to Symptom Chart — Transmission (Manual) and Transfer Case
Noise/Vibration .
6. Shifting
„Noise or vibration condition related to the transmission (automatic). GO to
Symptom Chart — Transmission (Automatic) Noise/Vibration .
„ Noise or vibration related to the transmission (manual). GO to Symptom Chart —
Transmission (Manual) and Transfer Case Noise/Vibration .
7. Engaged in four- wheel drive. GO to Symptom Chart — Transmission (Manual) and
Transfer Case Noise/Vibration .
8. Cruising speeds
„Accelerator pedal vibration. GO to Symptom Chart — Engine Noise/Vibration .
„ Driveline vibration. GO to Symptom Chart — Driveline Noise/Vibration .
„ A shimmy or shake. GO to Symptom Chart — Tire Noise/Vibration .
9. Driving at low/medium speeds Klj . 11 ba
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FORD MUSTANG 2003 Workshop Manual �„
A wobble or shudder. GO to Symptom Chart — Tire Noise/Vibration .
2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart — Sus

Page 60 of 4378

FORD MUSTANG 2003 Workshop Manual �z
No contact with side
glass. �z
ADJUST the door glass.
�z No contact with glass
runs at both ends of
belt line seal. �z
ADJUST the belt line seal
or ADD foam at the seal
ends.
�z Belt line

z
No contact with side
glass. z
ADJUST the door glass.
z No contact with glass
runs at both ends of
belt line seal. z
ADJUST the belt line seal
or ADD foam at the seal
ends.
z Belt line seal damaged. zINSTALL a new seal.
z Air leak at outer
belt line z
Belt line seal installed
incorrectly on flange
(no glass contact). z
ADJUST the seal.
z Belt line seal does not
contact the glass. z
ADJUST the door glass.
z No contact with glass
runs at both ends of
belt line seal. z
ADJUST the belt line
seal/ADD foam at the seal
ends.
z Belt line seal damaged. zINSTALL a new seal.
z Draft at inner
door
handle/speaker
opening z
Hole in watershield. zSEAL the hole with a
suitable tape.
z Watershield
misaligned. z
REALIGN the watershield.
INSTALL a new
watershield if the pressure
sensitive adhesive fails.
z Exterior door handle
seal
misaligned/damaged. z
REALIGN or INSTALL a
new seal as necessary.
z Wind noise from
side view mirror z
Outside mirror housing
misaligned. z
REALIGN with the edges
shingled correctly and no
gaps.
z Mirror sail gasket
folded/misaligned. z
REINSTALL with the
gasket unfolded and
aligned correctly.
z Mirror housing trim cap
installed incorrectly. z
REINSTALL with the
edges shingled to the air
flow.
z Air leak through mirror
housing hinge. z
Fully ENGAGE the mirror
into its operating
position/USE foam to
block the air path through
the hinge.
z Inner sail trim installed
incorrectly. z
REINSTALL the sail
trim/ADJUST the door
trim.
z Inner sail gasket/barrier
installed incorrectly. z
REINSTALL the trim
cover with the
gasket/barrier aligned
correctly.
z Air path through wiring
bundle/fastener access
holes. z
BLOCK the air path(s)
with foam/tape.
z Exposed fastener
access hole on mirror
housing/sail. z
INSTALL a new cap if it is
missing.
z Air leak around
perimeter of fixed z
Gaps in the sealant
bead. z
APPLY approved sealant. Klj . 13 ba
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Page 61 of 4378

FORD MUSTANG 2003 Workshop Manual glass
�zAir traveling up
windshield molding
along A- pillar. �z
INSTALL foam rope the
full length of the A- pillar.
�z Windshield/backlite
misaligned or not
installed correctly. �z
REINSTALL

glass
zAir traveling up
windshield molding
along A- pillar. z
INSTALL foam rope the
full length of the A- pillar.
z Windshield/backlite
misaligned or not
installed correctly. z
REINSTALL the
windshield/backlite.
z Rear hood seal at base
of windshield
misaligned/damaged. z
REALIGN or INSTALL a
new seal as necessary.
z Air leak at cowl zCowl gasket
misaligned/damaged. z
REALIGN or INSTALL a
new seal as necessary.
z Air leak around
liftgate perimeter z
Loose fit seal. zPINCH the seal carrier to
improve retention on the
seal flange or INSERT
foam in the carrier.
z Seal misaligned. zREINSTALL the seal.
z Liftgate misaligned. zREALIGN the liftgate.
CHECK the liftgate fit in
the body opening and
ADJUST as necessary.
z Scuff plate misaligned. zREINSTALL the scuff
plate.
z Seal or seal push pins
damaged. z
INSTALL a new seal.
z Air leak around
the liftgate flip
window
perimeter z
Loose fit seal. zPINCH the seal carrier to
improve the retention to
the seal flange.
z Seal misaligned. zREINSTALL the seal.
z Glass misaligned. zREALIGN the glass.
z Seal damaged. zINSTALL a new seal.
z Wind noise from
antenna z
Shape of antenna. zINSTALL an antenna boot
or a spiral antenna.
z Air leak around
antenna cable access
hole. z
INSPECT the antenna
access hole grommet.
REPAIR as necessary.
z Air leak from
closed roof
opening panel z
Seal installed
incorrectly. z
REINSTALL the seal.
z Roof opening panel
glass/door misaligned. z
REALIGN the roof
opening panel glass/door.
z Roof opening panel
damaged. z
INSTALL a new roof
opening panel.
z Buffeting from an
open roof
opening panel z
Wind deflector
inoperative/damaged. z
REPAIR or INSTALL a
new wind deflector as
necessary.
z Wind deflector height
incorrect. z
ADJUST the wind
deflector higher.
z Wind noise
created by
airflow over or
behind body
panels z
Fender splash shield
misaligned. z
REALIGN the fender
splash shield. Klj . 14 ba
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FORD MUSTANG 2003 Workshop Manual �z
Body panel misaligned
(exposed edge). �z
REALIGN the appropriate
body panel.
�z Hood misaligned (front
margin). �z
CHECK hood gaps and fit.
ADJUST the hood as
necessary.
�z Front grille ed

z
Body panel misaligned
(exposed edge). z
REALIGN the appropriate
body panel.
z Hood misaligned (front
margin). z
CHECK hood gaps and fit.
ADJUST the hood as
necessary.
z Front grille edge noise. zAPPLY foam in the hollow
areas behind the louvers.
z Wind noise
created by grille
opening panel z
Grille relationship to
leading edge on hood. z
ADJUST the grille
opening panel forward to
eliminate wind noise.
z Sharp edges due to
material imperfections. z
REMOVE the sharp
edges (no damage to
visible surface).
z Wind noise from
air extractor z
Air extractor housing
seated incorrectly. z
REINSTALL the air
extractor housing.
z Air extractor housing or
flaps damaged. z
INSTALL a new air
extractor.
z Air leak at top of
A-pillar —
vehicles with a
convertible top z
Seal at windshield
header installed
incorrectly. z
REINSTALL the seal.
z Seal pinched. zFILL the seal with foam to
reshape it.
z Gap between side rail
and header seal at A-
pillar. z
ADJUST the J-hook/vinyl
top.
z Air leak at rear
quarter glass
(division bar) —
vehicles with a
convertible top z
No contact between
front side glass and
quarter glass division
bar. z
ADJUST the front side
glass regulator and the
rear quarter glass
regulator.
z Air leak or wind
noise from top of
side glass —
vehicles with a
convertible top z
Gap between side rail
and vinyl top. z
ADD additional foam tape
to seal between the side
rail and the vinyl top.
z Seal at windshield
header installed
incorrectly. z
REINSTALL the seal.
z Seal damaged
between side rail and
vinyl top. z
INSTALL a new seal.
z Vinyl top damaged. zINSPECT the vinyl top.
INSTALL a new vinyl top
as necessary.
z Air leak or wind
noise at
windshield
header —
vehicles with a
convertible top z
Vinyl top not flush with
header. z
ADJUST the J-hook to
lower the top to achieve a
flush condition.
z Seal at windshield
header installed
incorrectly. z
REINSTALL the seal.
z Header seal not flush zREINSTALL the seal. Klj . 15 ba
702003 Mustang Workshop Manual
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Page 63 of 4378

FORD MUSTANG 2003 Workshop Manual with header.
�z Convertible top
flapping with the
top up �z
Vinyl top contacting
interior headliner. �z
Working from front to
back, INSTALL a 6.35 mm
(0.25 in) foam sheet
between the headline

with header.
z Convertible top
flapping with the
top up z
Vinyl top contacting
interior headliner. z
Working from front to
back, INSTALL a 6.35 mm
(0.25 in) foam sheet
between the headliner
and the vinyl top at the
suspected area. Allow a
clearance of 50 mm (2 in)
-75 mm (3 in) away from
the roof bows and the side
rails.
z Noise from roof
rack z
Roof rack rails or
crossbars loose. z
TIGHTEN the fasteners.
z Roof rack fasteners
missing. z
INSTALL the approved
fasteners.
z Roof rack crossbars
installed backward. z
REINSTALL the
crossbars.
z Roof rack rub strips
partially lifting from
roof. z
REAPPLY adhesive or
fasteners or INSTALL new
rub strips as necessary.
z Roof rack gaskets
loose or misaligned. z
REINSTALL the gasket.
z Wind noise from
bug
shield/exterior
windshield sun
visor z
Turbulence created by
location and shape. z
REMOVE per customer
direction if it is a dealer
installed option. Symptom Chart—
Brake Noise/Vibration Condition
Possible Sources Action
z Rattling noise zCaliper
mounting bolts
loose. z
CHECK the caliper bolts.
TIGHTEN to specifications.
REFER to Section 206 - 03
for front disc brakes or
Section 206
- 04 for rear
disc brakes.
z Damaged or
worn caliper
pins or
retainers. z
CHECK the caliper pins
and retainers for lubrication
and correct fit. LUBRICATE
or INSTALL new
components as necessary.
z Missing or
damaged anti-
rattle clips or
springs. z
CHECK the brake pads for
missing clips or broken
springs. INSTALL new
components as necessary.
REFER to Section 206 - 03
for front disc brakes or
Section 206
- 04 for rear
disc brakes.
z Loose brake
disc shield. z
TIGHTEN the brake disc
shield bolts to specification.
REFER to Section 206 - 03 .
z Clicking noise— with
brakes applied with
ABS brakes z
ABS hydraulic
control unit. z
Acceptable condition.
z Squealing noise— zDisc brake zAcceptable condition. Klj . 16 ba
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Page 64 of 4378

FORD MUSTANG 2003 Workshop Manual occurs on first
(morning) brake
application
pads.
Caused by humidity and
low disc brake pad
temperature.
�z Squealing noise— a
continuous squeal �z
Disc brake pads
or linings worn
below m

occurs on first
(morning) brake
application
pads.
Caused by humidity and
low disc brake pad
temperature.
z Squealing noise— a
continuous squeal z
Disc brake pads
or linings worn
below minimum
thickness. z
INSTALL new disc brake
pads. REFER to Section 206 - 03 for front disc brake
pads or Section 206 - 04 for
rear disc brake pads.
z Squealing noise— an
intermittent squeal
brought on by cold,
heat, water, mud or
snow z
Disc brake pad. zAcceptable condition.
z Groaning noise—
occurs at low speeds
with brake lightly
applied (creeping) z
Disc brake
pads. z
Acceptable condition.
z Grinding noise—
continuous z
Disc brake pads
or linings worn
below minimum
thickness. z
INSPECT the disc brake
pads, brake discs and
attaching hardware for
damage. REPAIR or
INSTALL new components
as necessary. REFER to
Section 206 - 03 for front
disc brakes and Section 206 - 04 for rear disc brakes.
z Moaning noise zBrake linings
contaminated
with grease or
oil. z
INSPECT the brake pads
and shoes for
contamination. REPAIR or
INSTALL new components
as necessary. REFER to
Section 206 - 03 for front
disc brakes or Section 206 -
04 for rear disc brakes.
z Brake
vibration/shudder—
occurs when brakes
are applied z
Uneven disc or
drum wear.
z Uneven disc
brake pad or
lining transfer.
z Suspension
components. z
Go To Pinpoint Test A .
z Brake
vibration/shudder—
occurs when the brake
pedal is released z
Brake drag. zINSPECT the disc brake
pads or linings for
premature wear. REPAIR
or INSTALL a new caliper
or wheel cylinder as
necessary. REFER to
Section 206 - 03 for front
disc brakes and Section 206 - 04 for rear disc brakes.
Symptom Chart—
Driveline Noise/Vibration Condition
Possible Sources Action
z Axle howling or
whine— front or rear
axle z
Axle lubricant
low. z
CHECK the lubricant level.
FILL the axle to
specification.
z Axle housing zINSPECT the axle housing Klj . 17 ba
702003 Mustang Workshop Manual
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