2003 FORD MUSTANG park assist

NOTE:
A serpentine drive belt decreases the usefulness of this test. In these cases, use a
vibration analyzer, such as the VA, to pinpoint accessory vibrations. An electronic listening
device, such as an EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belts.
z Increase the engine rpm to where the concern occurs.
z If the vibration/noise is duplicated when carrying out this test, the belts and accessories are not
sources.
z If the vibration/noise was not duplicated when carrying out this test, install each accessory belt,
one at a time, to locate the source.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
zTest preparations include matching customer conditions (if known). If not known, document the
test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch
for up to three minutes.
z Park the vehicle where testing will occur. The vehicle must remain at or below the concern
temperature (if known) for 6- 8 hours.
z Before starting the engine, conduct a visual inspection under the hood.
z Turn the key on, but do not start the engine. Listen for the fuel pump, anti- lock brake system
(ABS) and air suspension system noises.
z Start the engine.
z CAUTION: Never probe moving parts.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find
the general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
z GO to Symptom Chart — Idle Noise/Vibration to assist with the diagnosis.
6: Check OASIS/TSBs/Repair History
After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for
related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s)
specified in that information.
If no information is available from these sources, carry out the vehicle preliminary inspection to
eliminate any obvious faults.
7: Diagnostic Procedure
Qualifying the concern by the particular sensation present can help narrow down the concern. Always
use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method
divides the problem into related areas to correct the customer concern.
zVerify the "symptom".
z Determine which "system(s)" can cause the "symptom".
„If a vibration concern is vehicle speed related, the tire and wheel rpm/frequency or
driveshaft frequency should be calculated.
„ If a vibration concern is engine speed related, the engine, engine accessory or engine
firing frequencies should be calculated. Klj . 9 ba
702003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

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
22003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Component Tests
Brake Booster
1. Check the hydraulic brake system for leaks or insufficient fluid.
2. With the transmission (7003) in NEUTRAL, stop the engine (6007) and apply the parking brake control (2780). Apply the brake pedal several times to exhaust all vacuum in the system.
3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no
motion is felt, the power brake booster system is not functioning. Continue with the following
steps.
4. Remove the vacuum booster hose from the check valve connection. Manifold vacuum must be available at the check valve end of the vacuum booster hose with the engine at idle speed and
the transmission in NEUTRAL. If the manifold vacuum is available to the power brake booster,
connect the vacuum booster hose to the power brake booster check valve and repeat Steps 2
and 3.
5. If no downward movement of the brake pedal is felt, install a new power brake booster.
6. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the vehicle stand for 10 minutes. Then apply the brake pedal with approximately 89 N (20 lb) of force. The
brake pedal feel should be the same as that noted with the engine operating. If the brake pedal
feels hard (no power assist), install a new power brake booster check valve and retest. If the
brake pedal feels spongy, bleed the hydraulic system to remove air. For additional information,
refer to Bleeding — System in this section. Check Valve z
Engine running at idle speed.
z CAUTION: Do not hold the brake pedal at 444 Nm
(100 lb) force for more than 5 seconds at a time.
z Apply brake pedal with approximately 444 Nm (100 lb)
force and hold.
z Check hydro-boost unit input seal, housing seal,
accumulator seal, piston seal and spool plug seal for
leakage.
z Is hydro- boost unit free of leaks? Yes
GO to
G6 .
No
INSTALL a new hydro- boost
unit. G6 CHECK RESERVE RETENTION
z
Engine running at idle speed.
z CAUTION: Do not hold the brake pedal at 444 Nm
(100 lb) force for more than 5 seconds at a time.
z Charge system to pressure by holding the steering wheel at
stop or by pressing the brake pedal with approximately 444
Nm (100 lb) force.
z Key in OFF position.
z Wait five seconds.
z Press brake pedal and observe if there is any power brake
reserve.
z Is there any power brake reserve? Yes
Hydro-
boost unit is OK.
No
INSTALL a new hydro- boost
unit. Klj . 13 ba
152003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

GENERAL PROCEDURES
Parking Brake Cable Tension Release
1. CAUTION: If any component in the parking brake system requires repair or if the
rear axle housing (4010) is removed, the cable tension must be released.
Place the parking brake control (2780) in the released position.
2. Remove the console. For additional information, refer to Section 501 - 12 .
3. With an assistant inside the vehicle, raise and support the vehicle. For additional information, refer to Section 100 - 02 .
4. Pull the parking brake cable and equalizer rearward.
5. CAUTION: Do not remove the steel pin until the parking brake cable and
equalizer/rear cable and conduits are connected to the parking brake control. Pin
removal releases the tension in the ratchet wheel causing the spring to unwind and
release tension. Insert a steel pin through holes in the lever to the ratchet wheel. SECTION 206-
05: Parking Brake and Actuation 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

9. If an obvious cause for an observed or reported malfunction is found, correct the cause (if
possible) before proceeding to the next step.
10. If the fault is not visually evident, determine the symptom and proceed to the following symptom chart.
Steering System Symptom Definitions
Drift/Pull
Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the
vehicle going straight.
Drift describes what a vehicle with this condition does with hands off the steering wheel.
zA vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-
ahead path and require constant steering input in the opposite direction to counteract the effect.
z Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber).
Excessive Steering Wheel Play
Excessive steering wheel play is a condition in which there is too much steering wheel movement
before the wheels move. A small amount of steering wheel free play is considered normal.
Feedback
Feedback is a roughness felt in the steering wheel when the vehicle is driven over rough pavement.
Hard Steering or Lack of Assist
Hard steering or lack of assist is experienced when the steering wheel effort exceeds specifications.
Hard steering can remain constant through the full turn or occur near the end of a turn. It is important
to know the difference between hard steering/lack of assist and binding.
Hard steering or lack of assist can result from either hydraulic or mechanical conditions. It is extremely
important to know if this concern occurs during driving, during very heavy or static parking maneuvers.
Nibble
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road
surfaces and observed by the driver as small rotational oscillations of the steering wheel. Poor Returnability/Sticky Steering Visual Inspection Chart
Mechanical
z
Loose tie- rod ends
z Loose suspension components
z Loose steering column shaft universal joints
z Loose column intermediate shaft bolts
z Steering gear
z Binding or misaligned steering column
z Power steering pump
z Bent or pinched power steering hoses Klj . 4 ba
112003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Component Tests
Steering Linkage
1. NOTE: Excessive vertical motion of the studs relative to the sockets may indicate excessive
wear.
With the parking brake applied, perform the following:
zHave an assistant rotate the steering wheel back and forth 360 degrees and watch for
relative motion of the studs in the tie- rod end ball sockets.
z Watch for loose steering gear mounting.
2. Another method is to raise the front wheels (1007) off the ground, grasp the wheel at the front and rear and watch for excessive play or binding in the joints while trying to steer the wheels.
3. Install new steering components as necessary. For additional information, refer to the appropriate Group 2 steering section.
Turning Effort Test
NOTE: Make sure that the front wheels are properly aligned and the tire pressure is correct before
checking the effort.
1. Park the vehicle on dry concrete and set the parking brake.
2. Insert a thermometer into the power steering pump reservoir.
3. CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump will occur.
Idle the engine for two to three minutes. Turn the steering wheel from stop- to-stop several times
to warm the fluid to 50- 60°C (122-140°F).
4. With the engine running, attach special tool 211- 034 (T74P-3504-Y) to the rim of the steering
wheel.
5. Measure the pull required to turn the steering wheel one complete revolution in each direction. Refer to Steering Wheel Turning Effort under General Specifications in this section.
Pump Flow and Pressure Test WARNING: Do not touch the flowmeter during the test procedure, or severe burns and
serious injury may occur.
1. CAUTION: Make sure that the connection point will not interfere with any of the
engine accessory drive components or drive belts.
Install special tool 211- F001 (014-00207) at the high pressure port of the power steering pump.
Make sure the power steering analyzer gate valve is fully open. Klj . 8 ba
112003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

z
On some vehicles, the power steering pump high pressure port is inaccessible and the
special tool should then be installed either at the steering gear or at a point in the high
pressure line between the power steering pump and the steering gear.
2. Place a dial thermometer in the power steering pump reservoir.
3. Check the power steering fluid level. If necessary, add power steering fluid. zUse Motorcraft MERCON® Multi-Purpose ATF XT -2-QDX or MERCON® equivalent.
4. Install a digital tachometer.
5. CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump will occur.
Start the engine. Place the transmission in neutral. Set the parking brake. Raise the power
steering fluid temperature to 74- 80°C (165-175°F) by rotating the steering wheel fully to the left
and right several times.
6. Set the engine speed to 1500 rpm. Record the flow rate and pressure readings. zIf the flow rate is below the flow rate specification, a new power steering pump may need
to be installed. Continue with the test procedure.
z If the pressure reading is above the maximum pressure specification, then check power
steering hoses for kinks and restrictions.
7. Partially close the gate valve to obtain 750 psi. Set the engine speed at idle. Record the flow rate.
zIf the flow is less than the specified flow rate, then install a new power steering pump. For
additional information, refer to Section 211 - 02 .
8. CAUTION: Do not allow the gate valve to remain closed for more than 5 seconds.
Completely close and partially open the gate valve 3 times. Record the pressure relief valve
actuation pressure reading. zIf the pressure does not meet the relief pressure specification, install a new power
steering pump. For additional information, refer to Section 211 - 02 .
9. Set engine speed to 1500 rpm. Record the flow rate. zIf the flow rate varies more than 3.785 liters/minute (1 gallon/minute) from the initial flow
rate reading, install a new power steering pump. For additional information, refer to
Section 211 - 02 .
10. CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump will occur.
Set the engine speed at idle. Turn (or have an assistant turn) the steering wheel to the left and
right stops. Record flow rate and pressure readings at the stops.
zThe pressure reading at both stops should be nearly the same as the maximum pump
relief pressure.
z The flow rate should drop below 1.9 liters/minute (0.5 gallons/minute).
z If the pressure does not reach the maximum pump relief pressure or the flow rate does
not drop below the specified value, excessive internal leakage is occurring. Install a new
steering gear as necessary. For additional information, refer to Section 211 - 02 . Klj . 9 ba
112003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...