2003 FORD MUSTANG Workshop Manual

horn lock power steering open bonnet radiator cap height

Page 65 of 4378

FORD MUSTANG 2003 Workshop Manual damage.
for damage. REPAIR or
INSTALL a new axle as
necessary. REFER to
Section 205 - 02A for Ford
7.5 rear axles or Section 205 - 02B for Ford 8.8
integral axles.
�z Damaged or
worn wheel

damage.
for damage. REPAIR or
INSTALL a new axle as
necessary. REFER to
Section 205 - 02A for Ford
7.5 rear axles or Section 205 - 02B for Ford 8.8
integral axles.
z Damaged or
worn wheel
bearings or axle
bearings. z
CHECK for abnormal wheel
bearing play or roughness.
REFER to Wheel Bearing Check in this section.
ADJUST or INSTALL new
wheel bearings as
necessary.
z Damaged or
worn differential
ring and pinion. z
INSPECT the ring and
pinion ring for abnormal
wear patterns or broken
teeth. INSTALL a new ring
and pinion as necessary.
REFER to Section 205 - 02A
for Ford 7.5 rear axles or
Section 205
- 02B for Ford
8.8 integral axles.
z Damaged or
worn differential
side or pinion
bearings. z
CHECK for abnormal
bearing play or roughness.
INSTALL new bearings as
necessary.
z Damaged or
worn differential
side gears and
pinion gears. z
DISASSEMBLE the
differential carrier. INSPECT
the side and pinion gears for
abnormal wear patterns or
broken teeth. INSTALL new
gears as necessary. REFER
to Section 205 - 02A for Ford
7.5 rear axles or Section 205 - 02B for Ford 8.8
integral axles.
z Driveline clunk— loud
clunk when shifting
from reverse to drive z
Incorrect axle
lubricant level. z
CHECK the lubricant level.
FILL the axle to
specification.
z Excessive
backlash in the
axle or
transmission. z
CARRY OUT a total
backlash check. REFER to
Section 205 - 00 .
z Damaged or
worn pinion
bearings. z
CHECK for abnormal
bearing play or roughness.
INSTALL new bearings as
necessary. REFER to
Section 205 - 02A for Ford
7.5 rear axles or Section 205 - 02B for Ford 8.8
integral axles.
z Damaged or
worn universal
joints (U- joints). z
INSPECT the U- joints for
wear or damage. INSTALL
new U- joints as necessary.
REFER to Section 205 - 01 .
z Loose
suspension
components. z
INSPECT the suspension
for damage or wear.
REPAIR or INSTALL new Klj . 18 ba
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FORD MUSTANG 2003 Workshop Manual components as necessary.
�z Broken
powertrain
mounts. �z
INSPECT the powertrain
mounts. INSTALL new
mounts as necessary.
REFER to Section 303 - 01A
for 3.8L engines or
Section 303 - 01B fo

components as necessary.
z Broken
powertrain
mounts. z
INSPECT the powertrain
mounts. INSTALL new
mounts as necessary.
REFER to Section 303 - 01A
for 3.8L engines or
Section 303 - 01B for 4.6L (2V)
engines.
z Idle speed too
high. z
CHECK for the correct idle
speed.
z Driveline clunk—
occurs as the vehicle
starts to move
forward following a
stop z
Worn or galled
driveshaft slip-
yoke splines. z
CLEAN and INSPECT the
splines of the yoke for a
worn or galled condition.
INSTALL a new yoke as
necessary. REFER to
Section 205 - 01 .
z Worn or galled
driveshaft and
coupling shaft
splines. z
CLEAN and INSPECT the
splines of the driveshaft and
coupling shaft for a worn or
galled condition. INSTALL a
new driveshaft assembly as
necessary. REFER to
Section 205 - 01 .
z Loose rear leaf
spring U- bolts. z
CHECK the U- bolts for
loose nuts. TIGHTEN to
specification. REFER to
Section 204 - 02 .
z Driveline clunk (FWD
vehicles)—occurs
during acceleration or
from cruise to
coast/deceleration z
Damaged or
worn inboard
constant velocity
(CV) joint. z
INSPECT the inboard CV
joint and boot. REPAIR or
INSTALL a new CV joint as
necessary.
z Driveline clunk (4WD
vehicles)—occurs
during shift- on-the- fly
engagement z
Clutch relay.
z Shift motor.
z Transfer case.
z GEM. z
CHECK the 4WD
engagement system.
REPAIR or INSTALL new
components as necessary.
z Clicking, popping or
grinding— occurs
while vehicle is
turning z
Inadequate or
contaminated
lubrication in the
(CV) joints. z
CHECK the CV boots and
joints for wear or damage.
REPAIR or INSTALL new
components as necessary.
z Another
component
contacting the
halfshaft. z
CHECK the halfshafts and
the area around the
halfshafts. REPAIR as
necessary.
z Brake
components. z
INSPECT the front brakes
for wear or damage.
REPAIR as necessary.
REFER to Section 206 - 03 .
z Steering
components. z
INSPECT the drag link,
inner and outer tie- rods or
idler arm for wear or
damage. REPAIR as
necessary. REFER to
Section 211 - 02 .
z Suspension
components. z
INSPECT the upper and
lower ball joints for wear or
damage. REPAIR as
necessary. REFER to Klj . 19 ba
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FORD MUSTANG 2003 Workshop Manual Section 204 - 01 .
�z Damaged or
worn wheel
bearings �z
CHECK for abnormal wheel
bearing play or roughness.
Refer to Wheel Bearing Check in this section.
ADJUST or INSTALL new
wheel bearin

Section 204 - 01 .
z Damaged or
worn wheel
bearings z
CHECK for abnormal wheel
bearing play or roughness.
Refer to Wheel Bearing Check in this section.
ADJUST or INSTALL new
wheel bearings as
necessary.
z Clicking or
snapping— occurs
when accelerating
around a corner z
Damaged or
worn outboard
CV joint. z
INSPECT the outboard CV
joint and boot. REPAIR or
INSTALL a new CV joint as
necessary.
z High pitched
chattering— noise
from the rear axle
when the vehicle is
turning z
Incorrect or
contaminated
lubricant. z
CHECK the vehicle by
driving in tight circles (5
clockwise, 5
counterclockwise). FLUSH
and REFILL with the
specified rear axle lubricant
and friction modifier as
necessary.
z Damaged or
worn differential
(differential side
gears and pinion
gears). z
DISASSEMBLE the
differential assembly.
INSPECT the differential
case, pin and gears for wear
or damage. REPAIR or
INSTALL a new differential
as necessary. REFER to
Section 205 - 02A for Ford
7.5 rear axles or Section 205 - 02B for Ford 8.8
integral axles.
z Buzz—buzzing noise
is the same at cruise
or coast/deceleration z
Damaged or
worn tires. z
CHECK for abnormal tire
wear or damage. INSTALL a
new tire as necessary.
REFER to Section 204 - 04 .
z Incorrect
driveline angles. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to
Section 205 - 00 .
z Rumble or boom—
noise occurs at
coast/deceleration,
usually driveshaft
speed related and
noticeable over a
wide range of speeds z
Driveshaft is
out-of- balance. z
CHECK the driveshaft for
damage, missing balance
weights or undercoating.
CHECK the driveshaft
balance. CARRY OUT a
driveline vibration test.
REFER to Section 205 - 00 .
z U-joints binding
or seized. z
ROTATE the driveshaft and
CHECK for rough operation
or seized U- joints. INSTALL
new U- joints as necessary.
REFER to Section 205 - 01 .
z Excessive
pinion flange
runout. z
CARRY OUT a runout
check. REPAIR as
necessary. REFER to
Section 205 - 00 .
z Grunting— normally
associated with a
shudder experienced
during acceleration z
Driveshaft slip
yoke binding. z
CLEAN and LUBRICATE
the male and female
splines. Klj . 20 ba
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FORD MUSTANG 2003 Workshop Manual from a dead stop
�zLoose rear
spring U- bolts. �z
INSPECT the rear
suspension. TIGHTEN the
U-bolt nuts to specification.
REFER to Section 204 - 02 .
�z Howl— can occur at
various speeds an

from a dead stop
zLoose rear
spring U- bolts. z
INSPECT the rear
suspension. TIGHTEN the
U-bolt nuts to specification.
REFER to Section 204 - 02 .
z Howl— can occur at
various speeds and
driving conditions.
Affected by
acceleration and
deceleration z
Incorrect ring
and pinion
contact,
incorrect
bearing preload
or gear damage. z
CHECK the ring and pinion
and bearings for damage.
INSPECT the ring and
pinion wear pattern. REFER
to Checking Tooth Contact
Pattern and Condition of the
Ring and Pinion component
test in this section. ADJUST
or INSTALL new
components as necessary.
REFER to Section 205 - 02A
for Ford 7.5 rear axles or
Section 205
- 02B for Ford
8.8 integral axles.
z Chuckle— heard at
coast/deceleration.
Also described as a
knock z
Incorrect ring
and pinion
contact or by
damaged teeth
on the coast
side of the ring
and pinion. z
CHECK the ring and pinion
for damage. INSPECT the
ring and pinion wear pattern.
REFER to Checking Tooth
Contact Pattern and
Condition of the Ring and
Pinion component test in
this section. ADJUST or
INSTALL new components
as necessary. REFER to
Section 205 - 02A for Ford
7.5 rear axles or Section 205 - 02B for Ford 8.8
integral axles.
z Knock— noise occurs
at various speeds.
Not affected by
acceleration or
deceleration z
Gear tooth
damage to the
drive side of the
ring and pinion. z
CHECK the differential case
and ring and pinion for
damage. INSTALL new
components as necessary.
REFER to Section 205 - 02A
for Ford 7.5 rear axles or
Section 205
- 02B for Ford
8.8 integral axles.
z Excessive axle
shaft end play.
(Vehicles with
integral axles). z
CHECK the axle end play
using a dial indicator.
INSTALL a new axle shaft
or side gears as necessary.
REFER to Section 205 - 02A
for Ford 7.5 rear axles or
Section 205
- 02B for Ford
8.8 integral axles.
z Scraping noise— a
continuous low
pitched noise starting
at low speeds z
Worn or
damaged pinion
bearings. z
CHECK the pinion bearings.
INSTALL new pinion
bearings as necessary.
REFER to Section 205 - 02A
for Ford 7.5 rear axles or
Section 205
- 02B for Ford
8.8 integral axles.
z Driveline shudder—
occurs during
acceleration from a
slow speed or stop z
Rear drive axle
assembly
mispositioned. z
CHECK the axle mounts
and the rear suspension for
damage or wear. REPAIR
as necessary. Klj . 21 ba
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FORD MUSTANG 2003 Workshop Manual �z
Loose rear
spring U- bolts. �z
INSPECT the U- bolts.
TIGHTEN the U- bolt nuts to
specification. REFER to
Section 204 - 02 .
�z Incorrect or high
CV joint
operating angle. �z
CHECK vehicle

z
Loose rear
spring U- bolts. z
INSPECT the U- bolts.
TIGHTEN the U- bolt nuts to
specification. REFER to
Section 204 - 02 .
z Incorrect or high
CV joint
operating angle. z
CHECK vehicle ride height
is within limits. REPAIR as
necessary. REFER to
Section 206 - 00 .
z Damaged or
worn front
suspension
components. z
CHECK for a loose stabilizer
bar, damaged or loose
strut/strut bushings or loose
or worn ball joints. INSPECT
the steering linkage for wear
or damage. REPAIR or
INSTALL new components
as necessary.
z Driveline angles
out of
specification. z
CHECK for correct driveline
angles. REPAIR as
necessary. REFER to
Section 205 - 00 .
z U-joints binding
or seized. z
ROTATE the driveshaft and
CHECK for rough operation
or seized U- joints. INSTALL
new U- joints as necessary.
REFER to Section 205 - 01 .
z Binding,
damaged or
galled splines
on the driveshaft
slip- yoke z
CLEAN and INSPECT the
splines of the slip- yoke,
driveshaft and coupling
shaft for a worn, damaged
or galled condition.
INSTALL a new slip- yoke or
driveshaft assembly as
necessary. REPAIR as
necessary. REFER to
Section 205 - 01 .
z Driveline vibration—
occurs at cruising
speeds z
U-joints are
worn. z
CHECK for wear or incorrect
seating. INSTALL new U-
joints as necessary. REFER
to Section 205 - 01 .
z Worn or
damaged
driveshaft center
bearing support. z
CHECK the insulator for
damage or wear. ROTATE
the driveshaft and CHECK
for rough operation.
INSTALL a new center
bearing support as
necessary. REFER to
Section 205 - 01 .
z Loose axle
pinion flange
bolts. z
INSPECT the axle pinion
flange. TIGHTEN the pinion
flange bolts to specification.
REFER to Section 205 - 01 .
z Excessive axle
pinion flange
runout. z
CARRY OUT a Runout
Check. REPAIR as
necessary. REFER to
Section 205 - 01 .
z Driveshaft is
out-of- balance. z
CHECK the driveshaft for
damage, missing balance
weights or undercoating.
CHECK driveshaft balance. Klj . 22 ba
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FORD MUSTANG 2003 Workshop Manual CARRY OUT a driveline
vibration test. REFER to
Section 205
- 00 . REPAIR as
necessary.
�z Binding or
damaged
splines on the
driveshaft slip-
yoke. �z
CLEAN and INSPECT the
splines of the sli

Page 71 of 4378

FORD MUSTANG 2003 Workshop Manual noise—
normally
accompanied by
vibration Powertrain/Drivetrain Mount Neutralizing in this
section.
�z Damaged or
misaligned exhaust
system. �z
INSPECT the exhaust
system for loose or brok

noise—
normally
accompanied by
vibration Powertrain/Drivetrain Mount Neutralizing in this
section.
z Damaged or
misaligned exhaust
system. z
INSPECT the exhaust
system for loose or broken
clamps and brackets.
CARRY OUT Exhaust System Neutralizing in this
section.
z Whistling noise—
normally
accompanied
with poor idle
condition z
Air intake system. zCHECK the air intake
ducts, air cleaner, throttle
body and vacuum hoses for
leaks and correct fit.
REPAIR or ADJUST as
necessary. REFER to
Section 303 - 12
z
Clunking noise zWater pump has
excessive end play or
imbalance. z
CHECK the water pump for
excessive end play.
INSPECT the water pump
with the drive belt off for
imbalance. INSTALL a new
water pump as necessary.
REFER to Section 303 -
03A .
z Generator has
excessive end play. z
CHECK the generator for
excessive end play.
REPAIR or INSTALL a new
generator. REFER to
Section 414 - 02 .
z Pinging noise zExhaust system leak. zINSPECT the exhaust
system for leaks. REPAIR
as necessary.
z Gasoline octane too
low. z
VERIFY with customer the
type of gasoline used.
CORRECT as necessary.
z Knock sensor
operation. z
CHECK the knock sensor.
INSTALL a new knock
sensor as necessary.
REFER to Section 303 - 14 .
z Incorrect spark
timing. z
CHECK the spark timing.
REPAIR as necessary.
z High operating
temperature. z
INSPECT cooling system
for leaks. CHECK the
coolant level. REFILL as
necessary. CHECK the
coolant for the correct mix
ratio. DRAIN and REFILL
as needed. CHECK engine
operating temperature is
within specifications.
REPAIR as necessary.
z Foul- out spark plug. zCHECK the spark plugs.
REPAIR or INSTALL new
spark plugs as necessary.
z Catalytic converter. zAcceptable noise.
z Knocking noise—
light knocking
noise, also z
Excessive clearance
between the piston
and the cylinder wall. z
Engine cold and at high
idle. Using an EngineEAR,
pull a spark plug or fuel Klj . 24 ba
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FORD MUSTANG 2003 Workshop Manual described as
piston slap. Noise
is most
noticeable when
engine is cold
with light to
medium
acceleration.
Noise disappears
as engine warms
injector connector until the
noise goes away. CARR

described as
piston slap. Noise
is most
noticeable when
engine is cold
with light to
medium
acceleration.
Noise disappears
as engine warms
injector connector until the
noise goes away. CARRY
OUT a cylinder bore
clearance to piston check.
INSTALL a new piston.
REFER to
Section 303 - 01A
for 3.8L engines or
Section 303 - 01B for 4.6L (2V)
engines.
z Knocking noise—
light double
knock or sharp
rap sound.
Occurs mostly
with warm engine
at idle or low
speeds in DRIVE.
Increases in
relation to engine
load. Associated
with poor
lubrication history z
Excessive clearance
between the piston
and the piston pin. z
INSTALL a new piston or
piston pin. REFER to
Section 303 - 01A for 3.8L
engines or Section 303 - 01B
for 4.6L (2V) engines.
z Knocking noise—
light knocking
noise is most
noticeable when
engine is warm.
Noise tends to
decrease when
vehicle is
coasting or in
neutral z
Excessive clearance
between the
connecting rod
bearings and the
crankshaft. z
Engine warm and at idle.
Using an EngineEAR,
PULL a spark plug or fuel
injector connector until the
noise goes away. INSTALL
new bearings. REFER to
Section 303 - 01A for 3.8L
engines or Section 303 - 01B
for 4.6L (2V) engines.
z Knocking— deep
knocking noise.
Noise is most
noticeable when
engine is warm,
at lower rpm and
under a light load
and then at float z
Worn or damaged
crankshaft main
bearings. z
CARRY OUT DERU test.
CHECK for noise with
vehicle at operating
temperature, during
medium to heavy
acceleration. CHECK at
idle with injector
disconnected, noise does
not change. INSTALL new
main bearings. REFER to
Section 303 - 01A for 3.8L
engines or Section 303 - 01B
for 4.6L (2V) engines.
z Knocking noise—
occurs mostly
with warm engine
at light/medium
acceleration z
Spark plugs. zCHECK the spark plug for
damage or wear. INSTALL
new spark plugs as
necessary.
z Carbon accumulation
in combustion
chamber. z
REMOVE carbon from
combustion chamber.
z Whine or
moaning noise z
Air intake system. zCHECK the air cleaner and
ducts for correct fit.
INSPECT the air intake
system for leaks or
damage. REPAIR as
necessary. Klj . 25 ba
702003 Mustang Workshop Manual
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