2003 FORD MUSTANG brake

REMOVAL AND INSTALLATION
Spring —
Cobra
Removal CAUTION: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure can result in major service expense. A new part with
the same part number must be installed if installation becomes necessary. If substitution is
necessary, the part must be of the same finish and property class. Torque values must be used
as specified during reassembly to make sure of correct retention of these parts.
1. Raise the vehicle on a hoist. For additional information, refer to Section 100 - 02 .
2. Support the No. 1 crossmember with a jack stand.
3. Remove both wheel and tire assemblies. For additional information, refer to Section 204 - 04 .
4. Remove both mufflers. For additional information, refer to Section 309 - 00 .
5. Remove the driveshaft. For additional information, refer to Section 205 - 01 .
6. Disconnect the parking brake cable and conduits from the parking brake levers.
7. Remove the clip and disconnect the parking brake cable and conduits from the rear brake calipers. SECTION 204-
02: Rear Suspension 2003 Mustang Workshop Manual Special Tool(s)
Rotunda Powertrain Lift
014-00765 or Equivalent Klj . 1 ba
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8. Disconnect the parking brake cable and conduits from the knuckles (5A968/5A969).
9. Remove the bolts and the parking brake cable brackets.
10. Remove the bolts and the rear brake lines.
11. Remove the bolts and the ABS sensors. Klj . 2 ba
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11. Connect the rear brake lines and install the bolts.
12. Connect the parking brake cable and conduits to the lower suspension arm and bushings and
install the bolts.
13. Connect the parking brake cable and conduits to the knuckles. 14. Connect the parking brake cable and conduits to the rear brake calipers and install the clips. Klj . 7 ba
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15. Connect the parking brake cable and conduit to the parking brake levers.
16. Install the driveshaft. For additional information, refer to
Section 205 - 01 .
17. Install both mufflers. For additional information, refer to Section 309 - 00 .
18. Install both wheel and tire assemblies. For additional information, refer to Section 204 - 04 .
19. Remove the jack stand from the No. 1 crossmember.
20. Bleed the brake system. For additional information, refer to Section 206 - 00 .
21. Check wheel alignment. Adjust if necessary. For additional information, refer to Section 204 - 00 . Klj . 8 ba
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z
wheel bearing life.
z brake cooling.
New wheels need to be installed when vehicle's wheels:
zare bent.
z are cracked.
z are dented.
z are heavily corroded.
z are leaking.
z have elongated wheel hub bolt holes.
z have excessive lateral or radial runout.
Wheel and tire assemblies are attached by six wheel nuts.
It is mandatory to use only the tire sizes recommended on the tire chart attached to the vehicle. Larger
or smaller tires can damage the vehicle, affect durability, and require changing the speedometer
calibration. Make sure wheel size and offsets match those recommended for the tire in use. 1. Inspect for signs of uneven wear that may indicate a need for balancing, rotation, front suspension alignment, damaged tie- rod, or steering components.
2. Check tires for: zcuts.
z stone bruises.
z abrasions
z blisters.
z embedded objects.
3. Tread wear indicators are molded into the bottom of the tread grooves. Install a new tire when the indicator bands become visible.
Symptom Chart Symptom Chart Condition
Possible Sources Action
z Tires show
excess wear on
edge of tread z
Underinflated tires. zADJUST air pressure
in tires.
z Vehicle overloaded. zRETURN vehicle.
NOTIFY customer of
overload condition.
z High- speed cornering. zRETURN vehicle.
NOTIFY customer of
cause of condition.
z Incorrect ride height. zSET ride height.
z Incorrect wheel alignment. zSET alignment to
specification. REFER Klj . 2 ba
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to
Section 204 - 00 .
z Incorrect tire rotation
intervals. z
ADVISE customer of
condition. ROTATE
tires.
z Tires show
excess wear in
center of tread z
Tires overinflated. zADJUST air pressure.
z Other excessive
tire wear
problems z
Incorrect tire rotation
intervals. z
ADVISE customer of
condition. ROTATE
tires.
z Incorrect tire pressure. zADJUST pressure.
z Loose or leaking shock
absorbers. z
TIGHTEN or INSTALL
new shock absorbers
as necessary.
z Incorrect wheel alignment. zSET alignment to
specification. REFER
to Section 204 - 00 .
z Loose, worn or damaged
suspension components. z
REFER to Section 204 - 00 .
z Wheel and tire assembly
out of balance. z
BALANCE wheel and
tire assembly.
z Excessive lateral or radial
runout of wheel. z
REFER to Section 100 - 04 .
z Wobble or
shimmy z
Damaged wheel bearings. zREFER to Section 204 - 00 .
z Loose or damaged
suspension components. z
REFER to Section 204 - 00 .
z Bent wheel. zINSTALL a new wheel
as necessary.
z Damaged tire. zINSTALL a new tire as
necessary.
z Loose wheel nuts. zTIGHTEN to
specification.
z High- speed
shake z
Wheel hub face/pilot/bolt
circle runout.
z Tires/wheels.
z Wheel bearings.
z Suspension/steering
linkage.
z Engine.
z Transmission.
z Brake discs/imbalance. z
REFER to Section 100 - 04 .
z Vehicle vibration zDriveline — engine.
z Tires. z
REFER to Section 100 - 04 . Klj . 3 ba
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GENERAL PROCEDURES
Wheel Leaks
WARNING: Wheel repairs that use welding or peening are not approved. An inner tube is
not an acceptable repair for leaking wheels or tires.
If the air pressure in a tire mounted on an aluminum wheel is found to be low, perform the
following procedure before considering installation of a new wheel.
1. Remove the tire and wheel assembly, and inspect the wheel for structural damage. If none exists, go to Step 2. If the wheel is damaged, install a new wheel.
2. With the tire mounted on the wheel, locate the air leak using a water bath or equivalent method, and mark the location. Check the complete wheel for possible additional leaks. When leaks are
marked, dismount the tire marking valve location on the tire for correct indexing.
3. On the tire side of the wheel, thoroughly clean the leaking area with an appropriate choke cleaner or use sandpaper of approximately 80- grit to remove all contamination. Using the
sandpaper, score the surface of the leaking area to improve adhesion of the sealer. If the valve
stem is close to the area, remove it.
4. Use a clean cloth to remove all cleaner or sanding dust.
5. NOTE: Do not use a torch containing oxyacetylene.
Heat the prepared area with a Heat Gun or a propane torch until aluminum wheel repair
compound flows. Apply the hot melt material over the prepared area using a liberal flow and
wiping action. Repair is most effective when heat is applied to the brake side of the rim, and the
sealer is melted by heat in the metal.
6. Apply only enough heat to melt the sealer, then remove the heat source. After repairing the leak, allow the wheel to cool until it can be handled safety.
7. CAUTION: Use caution when mounting the tire so as not to damage the sealer.
Index and assemble the tire and wheel. Inflate the tire to the recommended pressure as
indicated on the tire pressure decal.
8. Repeat Step 2 to verify repair.
9. When the repair is completed, balance the assembly and install it on the vehicle.
SECTION 204-
04: Wheels and Tires 2003 Mustang Workshop Manual Material
Item Specification
Professional Choke and
Linkage Cleaner
F8AZ-
19520- AB WSS-
M14P10-
B Aluminum Wheel Repair
Compound ESA-
M4G280-
A Klj . 1 ba
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Installation
1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign
material present on the mounting surfaces of the wheel and the surface of the wheel hub,
brake drum or brake disc that contacts the wheel. Installing wheels without correct
metal- to-metal contact at the wheel mounting surfaces can cause the wheel nuts to
loosen and the wheel to come off while the vehicle is in motion, causing loss of control.
Position the wheel and tire on the vehicle.
2. CAUTION: Failure to tighten the wheel nuts in a star pattern can result in high brake
disc runout, which will speed up the development of brake roughness, shudder and
vibration.
Install the wheel nuts hand- tight, then lower the vehicle. Tighten the wheel nuts to specification
in a star- pattern sequence.
3. Install the center cap, if so equipped. Klj . 2 ba
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