2003 FORD MUSTANG lock

10. Connect the shock absorber to the suspension lower arm and bushing and install the new bolt
and a new nut.
11. Tighten the nut.
12. Lower the suspension and remove the jack stand.
13. Apply Anti- Seize Lubricant to the rear brake anti- lock sensor where it contacts the axle housing
and install the anti- lock sensor.
z Use High Temperature Nickel Anti- Seize Lubricant F6AZ-9L494-AA or equivalent
meeting Ford specification ESE-M124A- A.
14. Install the rear brake disc. For additional information, refer to Section 206 - 04 .
15. Tighten the retainer. Klj . 8 ba
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DISASSEMBLY AND ASSEMBLY
Halfshaft Joint
Disassembly
1. CAUTION: Do not disassemble the halfshaft assembly. Install a new assembly if
worn or damaged.
Remove the halfshaft from the vehicle. For additional information, refer to Halfshaft in this
section.
2. If necessary, remove the dust seal assembly (2217). 1. Tap uniformly around the dust seal assembly.
2. Slide the dust seal assembly from the shaft.
3. Using a suitable bearing plate and a press, remove the rear brake anti- lock sensor indicator, if
necessary.
SECTION 205-
05: Rear Drive Halfshafts 2003 Mustang Workshop Manual Special Tool(s)
Driver
205-
199 (T83T-3132- A1) Hub Bearing Cup Replacer
205-
147 (T80T-4000- P) Sensing Ring Replacer
206-
041 (T89P-20202- A) Klj . 1 ba
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Assembly
1. Using the special tool and a hammer, install the new dust seal assembly, if removed.
2. CAUTION: Place only the inboard CV joint outer race land on the bearing plate. Do
not press against any other portion of the outer race or damage will occur.
If removed, using the special tools, the bearing plate and a suitable press, seat the rear brake
anti- lock sensor indicator against the inboard CV joint housing.
3. Install the halfshaft in the vehicle. For additional information, refer to Halfshaft in this section. Klj . 2 ba
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DESCRIPTION AND OPERATION
Brake System
Component Locations
SECTION 206-
00: Brake System — General Information 2003 Mustang Workshop Manual Item Part
Number Description
1 2C346 Four wheel anti-
lock brake system (4WABS) Klj . 1 ba
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The vehicle is equipped with a vacuum-
assisted or a hydro-boost power braking system. Refer to
Section 206 - 07 .
The braking system is a front- to-rear split hydraulic system. Refer to Section 206 - 06 .
The front wheel brakes utilize a dual piston brake caliper and disc brake system. Refer to Section 206 -
03 .
The rear brakes utilize a single piston brake caliper and disc brake system. Refer to Section 206 - 04 .
The parking brake system is a mechanical system that is controlled by an independent hand- operated
parking brake control and is self- adjusting. Refer to Section 206 - 05 .
A 4- wheel anti- lock brake system or anti-lock brake system with traction control (4WABS) is optional
equipment on all models except Cobra. Cobra has ABS and traction control as standard equipment.
Refer to Section 206 - 09A . hydraulic control unit and control module assy (non-
traction)
1 2C353 Four wheel anti-
lock brake system (4WABS)
hydraulic control unit and control module assy
(traction) 2 2B559 Hydro-Boost brake booster and brake master
cylinder assy 3 2B195 Vacuum brake booster and brake master cylinder
assy
4 2K327 Rear disc brake assy
5 2780 Parking brake control
6 2B119 Front disc brake assy Klj . 2 ba
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in the brake master cylinder reservoir are also indicators of system concerns.
If a wheel is locked and the vehicle must be moved, open a bleeder screw at the locked wheel (1007)
to let out enough fluid to relieve the pressure. Close the bleeder screw. This bleeding operation may
release the brakes but will not correct the cause of trouble. If this does not relieve the locked wheel
condition, repair the locked components before proceeding.
Inspect all hoses and connections. All unused vacuum connectors should be capped. Make sure
hoses and their connections are correctly secured and in good condition with no holes, soft or
collapsed areas.
Non-
Pressure Leaks
The only part of the brake system that could have a brake fluid loss that does not appear when the
system is under pressure is the brake master cylinder reservoir area. Brake fluid loss can be caused
by a missing or poorly- fitted brake master cylinder filler cap (2162), a punctured or otherwise damaged
brake master cylinder reservoir, a missing or damaged brake master cylinder filler cap gasket, or by
missing, damaged or poorly- fitted sealing grommets between the brake master cylinder (2140) and the
brake master cylinder reservoir.
The brake master cylinder reservoir grommets are not separately serviceable and must be installed
new as part of a new brake master cylinder reservoir.
Install a new flexible brake hose if it shows signs of softening, cracking or other damage.
When installing a new brake hose, position the hose to avoid contact with other vehicle components.
Road Test
Perform a road test to compare actual vehicle braking performance with the performance standards
expected by the driver. The ability of the test driver to make valid comparisons and detect performance
deficiencies will depend on experience.
The driver should have a thorough knowledge of brake system operation and accepted general
performance guidelines in order to make good comparisons and detect performance problems.
Select a road that is reasonably smooth and level. Gravel or bumpy roads are not suitable because the
surface does not allow the tires to grip the road equally. Avoid crowned roads.
A key factor in evaluating brake concerns is the deceleration rate. This varies from vehicle to vehicle
and with changes in operating conditions. It is evident how well the brakes are working after just a few
applications.
Avoid locking the brakes. Locked brakes are not an indication of braking efficiency.
Visual Inspection Chart Mechanical Electrical
z
Brake master cylinder
z Brake caliper piston
z Brake discs
z Brake pads z
Parking brake switch
z Damaged or corroded wiring harness
z Brake master cylinder fluid level switch Klj . 2 ba
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Always On
zParking brake.
z Brake fluid level.
z Vibration When
Brakes Are Applied z
Rear disc brakes.
z Front disc brakes. z
REFER to Section 100 -
04 .
z Brake Pedal Goes
Down Fast z
Brake fluid level. zFILL the brake master
cylinder reservoir.
BLEED the system.
z Air in system. zBLEED the system.
z Brake master
cylinder. z
PERFORM the brake
master cylinder
component test in this
section.
z The Brake Pedal
Eases Down Slowly z
Air in system. zBLEED the system.
REFER to Bleeding —
System in this section.
z Brake master
cylinder. z
PERFORM the brake
master cylinder
component test in this
section.
z Brake Lockup During
Light Brake Pedal
Force z
Disc brake
component.
z Parking brake
component.
z Anti- lock brake
control system. z
Go To Pinpoint Test C .
z Excessive/Erratic
Brake Pedal Travel z
Leak in hydraulic
system.
z Air in system.
z Disc brake caliper.
z Brake master
cylinder. z
Go To Pinpoint Test D .
z Brakes Drag zParking brake
component. z
REPAIR or INSTALL new
components as
necessary. REFER to
Section 206 - 05 .
z Disc brake caliper. zREPAIR or INSTALL a
new brake caliper as
necessary. REFER to
Section 206 - 03 and
Section 206 - 04 .
z Brake booster-to-
brake master
cylinder push rod
adjustment. z
ADJUST the push rod.
REFER to Section 206 -
07 .
z Brake master
cylinder. z
PERFORM the brake
master cylinder
component test in this
section.
z Excessive Brake
Pedal Effort z
Power brake
booster. z
PERFORM the brake
booster component test
in this section.
z Power brake
booster check
valve (2365). z
PERFORM the check
valve component test in
this section.
z Power brake
booster hose. z
REROUTE, REPAIR or
INSTALL a new brake Klj . 5 ba
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PINPOINT TEST C: BRAKE LOCKUP DURING LIGHT BRAKE PEDAL
FORCE z
Is the resistance greater than 10,000 ohms? No
REPAIR the ground short in
circuit 128 (VT/YE). TEST the
system for normal operation.
B6 CHECK DAYTIME RUNNING LIGHTS (DRL) MODULE
z
Disconnect: DRL Module C1030.
z Measure the resistance to ground at C124- 2.
z Is the resistance greater than 10,000 ohms? Yes
REPAIR the DRL module. TEST
the system for normal operation.
No
REPAIR the ground short in
circuit 22 (LB/BK) or 977
(VT/WH). TEST the system for
normal operation.
Test Step Result / Action to Take
C1 INSPECT THE TIRES
z
Inspect the tires for uneven or excessive
wear, correct pressure, correct size and
type.
z Are the tires OK? Yes
GO to
C2 .
No
CORRECT as necessary. RETEST for
normal operation. C2 CHECK THE BRAKE CALIPER
COMPONENTS z
Inspect the brake pads and brake discs for
wear, damage, contamination and correct
installation.
z Are the brake components OK? Yes
GO to
C3 .
No
CORRECT as necessary. RETEST for
normal operation. C3 CHECK THE PROPORTIONING VALVE
z
Install the gauges from the ABS brake and
pressure test kit on one front and one rear
bleeder screw.
z Apply 6895 kPa (1000 psi) to the front
brake system.
z Is the pressure in the rear system 3516- Yes
INSPECT the disc brake calipers and
INSTALL new calipers as necessary.
RETEST for normal operation.
No Klj . 9 ba
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