2003 FORD MUSTANG test G

6. For vehicles with a two-
piece hub and brake disc assembly:
z Match-mark before disassembly.
z Remove the brake disc.
z Clean the hub and brake disc mounting surfaces with metal surface cleaner.
z Using a die grinder with a mild abrasive (Scotch Brite® type), remove any rust or
corrosion from the hub and brake disc mounting surfaces.
z Align the match- marks and reinstall the brake disc on the hub.
7. CAUTION: Do not use a bench lathe to machine brake discs.
NOTE: The depth of cut must be between 0.10 and 0.20 mm (0.004 and 0.008 inch). Lighter
cuts will cause heat and wear. Heavier cuts will cause poor brake disc surface finish.
Using an on- car brake lathe, machine the brake discs. Follow the manufacturer's instructions.
After machining, make sure the brake disc still meets the thickness specification.
8. Using the special tools, verify that the brake disc lateral runout is now within specification. For additional information, refer to Section 206 - 00 .
9. Remove the special tool hub adapter.
10. Remove any remaining metal chips from the machining operation.
11. For vehicles with a two- piece hub and brake disc assembly:
z Remove the brake disc from the hub.
z Remove any remaining metal chips from hub and brake disc mounting surfaces and from
the ABS sensor.
z Apply a liberal amount of lubricant to the hub flange, pilot area and to the brake disc- to-
hub mounting surface.
z Using the match marks, mount the brake disc on the hub.
12. Install the brake caliper anchor plate and the brake caliper.
13. Install the tire and wheel assembly.
14. Test the system for normal operation. Klj . 2 ba
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GENERAL PROCEDURES
Powertrain/Drivetrain Mount Neutralizing
WARNING: The electrical power to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off
the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the
air springs, which can result in shifting of the vehicle during these operations.
1. Raise and support the vehicle.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts.
Move the vehicle in forward and reverse 0.6- 1.2 meters (2-4 ft).
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
SECTION 100-
04: Noise, Vibration and Harshness 2003 Mustang Workshop Manual Klj . 1 ba
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GENERAL PROCEDURES
Exhaust System Neutralizing
WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and
potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an
enclosed area.
WARNING: Exhaust system components are hot.
NOTE: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to
transmit vibration as if grounded.
1. WARNING: The electrical power to the air suspension system must be shut off prior
to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by
turning off the air suspension switch. Failure to do so can result in unexpected inflation
or deflation of the air springs, which can result in shifting of the vehicle during these
operations.
CAUTION: Make sure the system is warmed up to normal operating temperature, as
thermal expansion can be the cause of a strain problem.
Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last).
zVerify there is adequate clearance to prevent grounding at any point in the system. Make
sure that the catalytic converter and heat shield do not contact the frame rails.
z After neutralization, the rubber in the exhaust hangers should show some flexibility when
movement is applied to the exhaust system.
z With the exhaust system installed securely and cooled, the rear hanger should be angled
forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.
SECTION 100-
04: Noise, Vibration and Harshness 2003 Mustang Workshop Manual Klj . 1 ba
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Wheel Track
Dogtracking
Dogtracking or thrust angle is the condition in which the rear axle is not square to the chassis. Heavily
crowned roads can give the illusion of dogtracking.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel (3600)
corrections to maintain a straight path down a level road. Item Description
1 Body reinforcement
2 Ride height (shortest distance)
3 Rear axle
Item Part Number Description
1 — Front track
2 — Rear track
Item Part Number Description
1 — Vehicle centerline
2 — Axle centerline
3 — Thrust angle Klj . 4 ba
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DIAGNOSIS AND TESTING
Suspension System
Inspection and Verification
1. Road test. zVerify the customer's concern by performing a road test on a smooth road.
2. Inspect tires. zCheck the tire pressure with all normal loads in the vehicle and the tires cold. For
additional information, refer to the vehicle certification (VC) label.
z Verify that all tires are sized to specification.
z Inspect the tires for incorrect wear and damage.
3. Inspect chassis and underbody. zRemove any excessive accumulation of mud, dirt or road deposits from the chassis and
underbody.
4. Inspect for aftermarket equipment. zCheck for aftermarket changes to the steering, suspension, wheel and tire components
(such as competition, heavy duty, etc.) The specifications shown in this manual do not
apply to vehicles equipped with aftermarket equipment.
5. Inspect shock absorbers. All vehicles are equipped with gas- pressurized hydraulic shock absorbers. These shock
absorbers are not adjustable or refillable and cannot be repaired.
zOil Leak: A light film of oil (weepage) on the upper portion of the shock absorber is
permissible and is a result or correct shock lubrication. Weepage is a condition in which a
film of oil accumulates on the thin tube (body) and is normally noticed due to the
collection of dust in this area. If shock absorbers exhibit this weepage condition, they are
functional units and new shock absorbers should not be installed. Leakage is a condition
in which the entire shock absorber body is covered with oil and the oil will drip from the
shock absorber onto the pavement. If condition exists:
„Make sure fluid observed is not from sources other than the shock absorber.
„ Install a new shock absorber, if necessary.
z Vehicle Sag: Many times new shock absorbers are installed in an effort to solve a vehicle
sag concern. Shock absorbers by design are hydraulic damping units only and, unlike
suspension springs, do not support any suspension loads. Therefore, installing a new
shock absorber will not correct a vehicle sag concern.
z Installment in Pairs: In the past it was recommended that new shock absorbers be
installed in pairs if one unit became unrepairable. New shock absorbers no longer need
to be installed in pairs when only one unit is not repairable.
SECTION 204-
00: Suspension System — General Information 2003 Mustang Workshop Manual Visual Inspection Chart
Mechanical Klj . 1 ba
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z
Excessive front or
rear toe (rapid inner
or outer edge
wear). z
CHECK the wheel alignment.
ADJUST as necessary.
z Excessive negative
or positive camber
(rapid inner or outer
edge wear). z
CHECK the wheel alignment.
ADJUST as necessary.
z Tires out of balance
(tires cupped or
dished). z
BALANCE tires.
z Rough ride zStrut(s). zINSTALL new strut(s) as
necessary. REFER to Section 204 - 01 .
z Shock absorber(s). zINSTALL new shock absorber
(s) as necessary.
z Front coil springs or
rear springs (5560). z
INSTALL new front coil
springs or rear springs as
necessary. REFER to Section 204 - 01 or
Section 204 - 02 .
z Shimmy or
wheel tramp z
Loose wheel nut(s). zTIGHTEN to specification.
REFER to Section 204 - 04 .
z Loose front
suspension
fasteners. z
TIGHTEN to specification.
REFER to Section 204 - 01 .
z Front wheel bearing
(s). z
REFER to Wheel Bearing Inspection in this section.
z Wheel or tire
runout. z
REFER to Section 204 - 04 .
z Tire flatspotting. zREFER to Section 204 - 04 .
z Shock absorber(s). zINSTALL new shock absorber
(s) as necessary.
z Loose, worn or
damaged ball joint
(s). z
GO to the Ball Joint Inspection
component test in this section.
z Loose, worn or
damaged steering
components. z
REFER to Section 211 - 00 .
z Front wheel
alignment. z
CHECK the wheel alignment.
ADJUST as necessary.
z Sticky steering,
poor returnability z
Ball joints. zGO to the Ball Joint Inspection
component test in this section.
z Steering
components. z
REFER to Section 211 - 00 .
z Steering wheel
off- center z
Unequal front or
rear toe settings
(side-to- side). z
CHECK the wheel alignment.
ADJUST as necessary.
z Steering
components. z
REFER to Section 211 - 00 .
z Sway or roll zOverloaded,
unevenly or
incorrectly loaded
vehicle. z
NOTIFY the customer of
incorrect vehicle loading.
z Loose wheel nut(s). zTIGHTEN to specification. Klj . 3 ba
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REFER to
Section 204 - 04 .
z Strut(s). zINSTALL new strut(s) as
necessary. REFER to Section 204 - 01 .
z Shock absorber(s). zINSTALL new shock absorber
(s) as necessary.
z Loose front
stabilizer bar (5482)
or rear stabilizer
bar (5A772). z
TIGHTEN to specification.
REFER to Section 204 - 01 or
Section 204 - 02 .
z Worn stabilizer
assembly bushing
(s). z
INSTALL new bushing(s) as
necessary. REFER to Section 204 - 01 or
Section 204 - 02 .
z Front coil spring(s)
or rear spring(s). z
INSTALL new front coil
springs or rear springs as
necessary. REFER to Section 204 - 01 or
Section 204 - 02 .
z Vehicle leans to
one side z
Unevenly loaded or
overloaded vehicle. z
NOTIFY the customer of
incorrect vehicle loading.
z Front or rear
suspension
components. z
INSPECT the front and rear
suspension system. REPAIR
or INSTALL new suspension
components as necessary.
REFER to Section 204 - 01 or
Section 204 - 02 .
z Front coil springs or
rear springs. z
INSTALL new front coil
springs or rear springs as
necessary. REFER to Section 204 - 01 or
Section 204 - 02 .
z Incorrect ride
height. Lateral tilt
out of specification. z
CHECK ride height. INSTALL
new front coil springs or rear
springs as necessary. REFER
to Section 204 - 01 or
Section 204 - 02 .
z Vibration/noise zTire or wheel
runout.
z Tire flatspotting.
z Wheel bearings.
z Wheel hubs.
z Brake components.
z Suspension
components.
z Steering
components. z
REFER to Section 100 - 04 .
z Wander zUnevenly loaded or
overloaded vehicle. z
NOTIFY the customer of
incorrect vehicle loading.
z Ball joint(s). zGO to the Ball Joint Inspection
component test in this section.
z Front wheel bearing
(s). z
REFER to Wheel Bearing Inspection in this section.
z Loose, worn or
damaged
suspension
components(s). z
INSTALL new suspension
components as necessary.
REFER to Section 204 - 01 or
Section 204 - 02 .
z Loose suspension
fasteners. z
TIGHTEN to specification.
REFER to Section 204 - 01 or
Section 204 - 02 . Klj . 4 ba
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Component Tests
Ball Joint Inspection
1. Raise and support the vehicle. Refer to Section 100 - 02 .
2. Prior to performing any inspection of the ball joints, inspect the wheel bearings.
3. Position a safety stand beneath the front suspension lower arm (3079) to be tested.
4. While an assistant pulls and pushes the bottom of the tire, observe the relative movement between the lower spindle arm and the front suspension lower arm ball joint. Any movement at
or exceeding the specification indicates a worn or damaged lower ball joint. Install a new front
suspension lower arm. Refer to Section 204 - 01 . z
Steering
components. z
REFER to Section 211 - 00 .
z Wheel alignment. zCHECK wheel alignment.
ADJUST as necessary
(excessive total front toe out). Klj . 5 ba
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