2003 Mustang Workshop Manual – PDF DOWNLOAD
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2003 Mustang Workshop Manual – PDF DOWNLOAD
- The maintenance schedule is designed to protect against major repairs resulting from neglect or inadequate maintenance and to prolong the life of the vehicle. General Maintenance Information NOTE:
- This is a generic maintenance schedule for all Ford, Lincoln and Mercury vehicles. There may be items listed that do not apply to all vehicles. The Normal Schedule applies to operation of the vehicle under typical, everyday driving conditions.
- The maintenance frequency in this schedule typifies what the vast majority of vehicles will require. The listed services should be carried out at specified mileage intervals. There are, however, additional services required that only the noted vehicles require. If the vehicle is operated in one or more of the following special operating conditions, those additional services will be required.
- The special operating conditions are: towing or carrying heavy loads. extensive idling and/or driving at low speeds for long distances. driving in dusty conditions. off-road operation. There are also exceptions to the Normal Operating Schedule which will require more frequent maintenance for some components. Those exceptions are: natural gas and propane vehicles — fuel tank intervals.
- normal vehicle axle — maintenance and lubrication. police and taxi vehicles — maintenance and lubrication. engine oil and yellow coolant — time and mileage-based interval. Special Operating Condition Requirements When towing a trailer or using a camper or car-top carrier: Change engine oil and install a new oil filter every 4,800 km (3,000 miles) or 3 months.
- Change transfer case fluid every 96,000 km (60,000 miles). Change manual transmission fluid as required. Inspect and lubricate U-joints as required. During extensive idling and/or low speed driving for long distances, as in heavy commercial use such as delivery, taxi, patrol car or livery:
TABLE OF CONTENTS:
2003 Mustang Workshop Manual – PDF DOWNLOAD
1- General Information.................................................................................. 1 GROUP 00 Service Information........................................................................ 1 SECTION 100-01- Identification Codes - DESCRIPTION AND OPERATION................................ 1 SECTION 100-02 Jacking and Lifting - DESCRIPTION AND OPERATION.................................. 17 SECTION 100-03 Maintenance Schedule - DESCRIPTION AND OPERATION................................. 22 SECTION 100-04 Noise, Vibration and Harshness................................................... 33 DESCRIPTION AND OPERATION................................................................... 33 DIAGNOSIS AND TESTING....................................................................... 48 GENERAL PROCEDURES.......................................................................... 118 2 - Chassis............................................................................................. 126 04 - Suspension.................................................................................... 126 SECTION 204-00 Suspension System - General Information.......................................... 126 SPECIFICATIONS.............................................................................. 126 DESCRIPTION AND OPERATION................................................................... 128 DIAGNOSIS AND TESTING....................................................................... 134 GENERAL PROCEDURES.......................................................................... 140 Wheel Bearing Inspection................................................................ 140 Camber and Caster Adjustment—Front...................................................... 141 Camber Adjustment —Rear................................................................. 145 Toe Adjustment—Front.................................................................... 147 Toe Adjustment —Rear.................................................................... 150 SECTION 204-01 Front Suspension................................................................. 152 SPECIFICATIONS.............................................................................. 152 REMOVAL AND INSTALLATION.................................................................... 153 Wheel Studs............................................................................. 153 Wheel Hub and Bearing................................................................... 155 Arm —Lower.............................................................................. 157 Bar—Stabilizer.......................................................................... 159 Link —Stabilizer Bar.................................................................... 162 Bushing —Stabilizer Bar................................................................. 164 Spindle................................................................................. 167 Shock Absorber.......................................................................... 172 Spring.................................................................................. 177 SECTION 204-02 Rear Suspension.................................................................. 185 SPECIFICATIONS.............................................................................. 185 DESCRIPTION AND OPERATION................................................................... 187 REMOVAL AND INSTALLATION.................................................................... 189 Wheel Hub—Cobra......................................................................... 189 Wheel Studs............................................................................. 195 Upper Arm............................................................................... 197 Upper Arm —Cobra........................................................................ 201 Lower Arm............................................................................... 206 Stabilizer Bar.......................................................................... 208 Stabilizer Bar—Cobra.................................................................... 211 Link —Stabilizer Bar.................................................................... 214 Wheel Knuckle—Cobra..................................................................... 216 Toe Link—Cobra.......................................................................... 225 Spring—Coil............................................................................. 229 Spring —Cobra........................................................................... 234 Shock Absorber.......................................................................... 243 Damper.................................................................................. 246 SECTION 204-04 Wheels and Tires................................................................. 249 SPECIFICATIONS.............................................................................. 249 DESCRIPTION AND OPERATION................................................................... 251 DIAGNOSIS AND TESTING....................................................................... 254 GENERAL PROCEDURES.......................................................................... 258 REMOVAL AND INSTALLATION.................................................................... 260 05 - Driveline...................................................................................... 263 SECTION 205-00 Driveline System —General Information............................................ 263 SPECIFICATIONS.............................................................................. 263 DIAGNOSIS AND TESTING....................................................................... 265 GENERAL PROCEDURES.......................................................................... 284 SECTION 205-01 Driveshaft....................................................................... 288 SPECIFICATIONS.............................................................................. 288 DESCRIPTION AND OPERATION................................................................... 289 REMOVAL AND INSTALLATION.................................................................... 293 DISASSEMBLY AND ASSEMBLY.................................................................... 298 SECTION 205-02A Rear Drive Axle-Differential — Ford 7.5-Inch Ring Gear.......................... 306 SPECIFICATIONS.............................................................................. 306 DESCRIPTION AND OPERATION................................................................... 308 IN-VEHICLE REPAIR........................................................................... 311 Axle Shaft.............................................................................. 311 Rear Wheel Bearing and Axle Shaft Oil Seal.............................................. 315 Drive Pinion Flange and Drive Pinion Seal............................................... 318 Differential Housing Cover.............................................................. 323 Axle Housing Bushing.................................................................... 326 Drive Pinion............................................................................ 328 Differential Case....................................................................... 341 REMOVAL AND INSTALLATION.................................................................... 354 DISASSEMBLY AND ASSEMBLY.................................................................... 359 SECTION 205-02B Rear Drive Axle-Differential — Ford 8.8-Inch Ring Gear.......................... 365 SPECIFICATIONS.............................................................................. 365 DESCRIPTION AND OPERATION................................................................... 367 IN-VEHICLE REPAIR........................................................................... 370 Axle Shaft.............................................................................. 370 Rear Wheel Bearing and Axle Shaft Oil Seal.............................................. 374 Differential Housing Cover.............................................................. 377 Axle Housing Bushing.................................................................... 380 Drive Pinion............................................................................ 382 Differential Case....................................................................... 395 REMOVAL AND INSTALLATION.................................................................... 408 DISASSEMBLY AND ASSEMBLY.................................................................... 414 SECTION 205-02C Rear Drive Axle Differential — Ford 8.8-Inch IRS................................ 429 SPECIFICATIONS.............................................................................. 429 DESCRIPTION AND OPERATION................................................................... 431 IN-VEHICLE REPAIR........................................................................... 434 Stub Shaft Pilot Bearing and Seal....................................................... 434 Drive Pinion Flange..................................................................... 438 Pinion Seal............................................................................. 443 REMOVAL AND INSTALLATION.................................................................... 445 DISASSEMBLY AND ASSEMBLY.................................................................... 459 SECTION 205-05 Rear Drive Halfshafts............................................................ 494 SPECIFICATIONS.............................................................................. 494 DESCRIPTION AND OPERATION................................................................... 495 REMOVAL AND INSTALLATION.................................................................... 498 DISASSEMBLY AND ASSEMBLY.................................................................... 507 06 - Brake System.................................................................................. 510 SECTION 206-00 Brake System - General Information............................................... 510 SPECIFICATIONS.............................................................................. 510 DESCRIPTION AND OPERATION................................................................... 511 DIAGNOSIS AND TESTING....................................................................... 513 GENERAL PROCEDURES.......................................................................... 528 Bleeding —Components.................................................................... 528 Bleeding —System........................................................................ 534 Hydraulic Leak Check.................................................................... 538 Runout Check —Brake Disc and Hub........................................................ 539 SECTION 206-03 Front Disc Brake................................................................. 542 SPECIFICATIONS.............................................................................. 542 DESCRIPTION AND OPERATION................................................................... 543 REMOVAL AND INSTALLATION.................................................................... 546 Pads.................................................................................... 546 Brake Pads —Cobra....................................................................... 553 Caliper................................................................................. 557 Brake Caliper—Cobra..................................................................... 561 Brake Caliper Anchor Plate —Cobra....................................................... 564 Brake Caliper Anchor Plate.............................................................. 566 Disc.................................................................................... 568 Shield.................................................................................. 570 DISASSEMBLY AND ASSEMBLY.................................................................... 572 SECTION 206-04 Rear Disc Brake.................................................................. 577 SPECIFICATIONS.............................................................................. 577 DESCRIPTION AND OPERATION................................................................... 578 REMOVAL AND INSTALLATION.................................................................... 580 DISASSEMBLY AND ASSEMBLY.................................................................... 592 SECTION 206-05 Parking Brake and Actuation...................................................... 596 SPECIFICATIONS.............................................................................. 596 DESCRIPTION AND OPERATION................................................................... 597 DIAGNOSIS AND TESTING....................................................................... 599 GENERAL PROCEDURES.......................................................................... 602 REMOVAL AND INSTALLATION.................................................................... 604 SECTION 206-06 Hydraulic Brake Actuation........................................................ 614 SPECIFICATIONS.............................................................................. 614 DESCRIPTION AND OPERATION................................................................... 615 REMOVAL AND INSTALLATION.................................................................... 618 SECTION 206-07 Power Brake Actuation............................................................ 630 SPECIFICATIONS.............................................................................. 630 DESCRIPTION AND OPERATION................................................................... 631 GENERAL PROCEDURES.......................................................................... 635 REMOVAL AND INSTALLATION.................................................................... 637 SECTION 206-09A; Anti-Lock Control — Rear....................................................... 645 SPECIFICATIONS.............................................................................. 645 DESCRIPTION AND OPERATION................................................................... 646 DIAGNOSIS AND TESTING....................................................................... 647 REMOVAL AND INSTALLATION.................................................................... 663 Sensor Indicator —Rear.................................................................. 663 Hydraulic Control Unit.................................................................. 666 Module.................................................................................. 669 Sensor—Front............................................................................ 671 Sensor—Rear............................................................................. 674 SECTION 206-09B Anti-LocK Control — Traction Control............................................ 676 SPECIFICATIONS.............................................................................. 676 DESCRIPTION AND OPERATION................................................................... 677 DIAGNOSIS AND TESTING....................................................................... 678 REMOVAL AND INSTALLATION.................................................................... 698 Sensor Indicator —Rear.................................................................. 698 Hydraulic Control Unit.................................................................. 701 Module.................................................................................. 704 Sensor—Front............................................................................ 706 Sensor—Rear............................................................................. 709 Switch —Traction Control................................................................ 711 11 - Steering System................................................................................ 713 SECTION 211-00 Steering System - General Information............................................ 713 SPECIFICATIONS.............................................................................. 713 DESCRIPTION AND OPERATION................................................................... 715 DIAGNOSIS AND TESTING....................................................................... 718 GENERAL PROCEDURES.......................................................................... 729 System Flushing —Сll Power Steering Pump................................................ 729 System Flushing —Clll Power Steering Pump............................................... 731 Purging —Сll Power Steering Pump........................................................ 733 Purging —Clll Power Steering Pump....................................................... 736 Fill.................................................................................... 739 SECTION 211-02 Power Steering................................................................... 741 SPECIFICATIONS.............................................................................. 741 DESCRIPTION AND OPERATION................................................................... 743 REMOVAL AND INSTALLATION.................................................................... 749 Reservoir—Clll Pump..................................................................... 749 Pump —Сll............................................................................... 751 Pump —Clll.............................................................................. 754 Pulley—Cll Pump......................................................................... 757 Pulley— Clll Pump....................................................................... 759 Hose.................................................................................... 761 Cooler—Fluid............................................................................ 763 Gear.................................................................................... 765 DISASSEMBLY AND ASSEMBLY.................................................................... 769 SECTION 211-04 Steering Column.................................................................. 775 SPECIFICATIONS.............................................................................. 775 DESCRIPTION AND OPERATION................................................................... 776 GENERAL PROCEDURES.......................................................................... 780 REMOVAL AND INSTALLATION.................................................................... 786 Ignition Switch Lock Cylinder—Functional................................................ 786 Ignition Switch Lock Cylinder—Non-Functional............................................ 788 Wheel................................................................................... 791 Column.................................................................................. 793 Steering Column Shaft................................................................... 797 Coupling................................................................................ 799 DISASSEMBLY AND ASSEMBLY.................................................................... 801 SECTION 211-05 Steering Column Switches......................................................... 819 SPECIFICATIONS.............................................................................. 819 DESCRIPTION AND OPERATION................................................................... 820 DIAGNOSIS AND TESTING....................................................................... 821 REMOVAL AND INSTALLATION.................................................................... 829 3 - Powertrain.......................................................................................... 836 03 - Engine......................................................................................... 836 SECTION 303-00 Engine System - General Information.............................................. 836 SPECIFICATIONS.............................................................................. 836 DESCRIPTION AND OPERATION................................................................... 837 DIAGNOSIS AND TESTING....................................................................... 838 GENERAL PROCEDURES.......................................................................... 855 Sprockets............................................................................... 855 Rocker Arms —Cleaning................................................................... 856 Rocker Arms —Inspection................................................................. 857 Push Rods —Cleaning..................................................................... 858 Push Rods—Inspection.................................................................... 859 Camshaft Journal —Diameter.............................................................. 860 Camshaft Journal —Clearance, Push Rod Engines, Micrometer Method........................ 861 Camshaft Journal—Clearance, Plastigage Method........................................... 863 Camshaft End Play —Push Rod Engines..................................................... 865 Camshaft End Play —OHC Engines.......................................................... 867 Camshaft—Lobe Surface................................................................... 869 Camshaft Lobe Lift...................................................................... 870 Camshaft Runout......................................................................... 871 Crankshaft Main Bearing Journal —Diameter............................................... 873 Crankshaft Main Bearing Journal —Taper.................................................. 874 Crankshaft Main Bearing Journal —Clearance.............................................. 875 Crankshaft End Play..................................................................... 877 Crankshaft Runout....................................................................... 879 Crankshaft—Connecting RodJournal Taper, Out of Round.................................... 881 Cylinder Bore —Taper.................................................................... 882 Cylinder Bore —Out-of-Round............................................................. 883 Piston Inspection....................................................................... 884 Piston —Pin to Bore Diameter............................................................ 886 Piston —Diameter........................................................................ 888 Piston —to Cylinder Bore Clearance...................................................... 889 Piston—Selection........................................................................ 890 Piston —Ring End Gap.................................................................... 892 Piston —Ring-to-Groove Clearance........................................................ 894 Piston —Pin Diameter.................................................................... 896 Connecting Rod —Cleaning................................................................ 897 Connecting Rod —Large End Bore.......................................................... 898 Connecting Rod —Bushing Diameter........................................................ 899 Connecting Rod —Bend.................................................................... 900 Connecting Rod —Twist................................................................... 901 Connecting Rod —Piston Pin Side Clearance............................................... 902 Connecting Rod —Bearing Journal Clearance............................................... 903 Connecting Rod —Side Clearance.......................................................... 905 Roller Follower—Inspection.............................................................. 906 Valve Tappet—Inspection................................................................. 908 Valve —Stem Diameter.................................................................... 910 Valve Stem to Valve Guide Clearance..................................................... 911 Valve—Inspection........................................................................ 913 Valve —Guide Inner Diameter............................................................. 914 Valve —Guide Reaming.................................................................... 915 Valve —Spring Installed Length.......................................................... 916 Valve —Spring Free Length............................................................... 917 Valve—Spring Squareness................................................................. 918 Valve Spring Strength................................................................... 919 Valve —Seat Inspection.................................................................. 921 Valve—Seat Width........................................................................ 922 Valve —Seat Runout...................................................................... 923 Cylinder Head —Distortion............................................................... 924 Cylinder Bore —Cleaning................................................................. 925 Cylinder Block Core Plug Replacement.................................................... 926 Spark Plug Hole Thread Repair........................................................... 928 Spark Plug —Inspection.................................................................. 929 Exhaust Manifold —Inspection............................................................ 932 Bearing —Inspection..................................................................... 933 SECTION 303-01A Engine — 3.8L................................................................... 935 SPECIFICATIONS.............................................................................. 935 DESCRIPTION AND OPERATION................................................................... 941 DIAGNOSIS AND TESTING....................................................................... 950 IN-VEHICLE REPAIR........................................................................... 951 Upper Intake Manifold................................................................... 951 Lower Intake Manifold................................................................... 959 Valve Cover —LH......................................................................... 968 Valve Cover RH.......................................................................... 970 Crankshaft Pulley....................................................................... 973 Crankshaft Front Seal................................................................... 976 Engine Front Cover...................................................................... 978 Rocker Arm.............................................................................. 987 Push Rod................................................................................ 989 Valve Springs........................................................................... 991 Valve Tappets........................................................................... 994 Camshaft................................................................................ 996 Engine Dynamic Balance Shaft............................................................ 999 Timing Chain............................................................................1002 Exhaust Manifold —LH....................................................................1007 Exhaust Manifold RH.....................................................................1010 Cylinder Head LH........................................................................1013 Cylinder Head RH........................................................................1019 Oil Level Indicator and Tube............................................................1024 Oil Pan.................................................................................1026 Oil Pan Baffle..........................................................................1038 Flywheel................................................................................1039 Oil Pump Screen and Pickup Tube.........................................................1041 Flexplate...............................................................................1043 Crankshaft Rear Seal....................................................................1044 Engine Support Insulators...............................................................1047 REMOVAL.....................................................................................1055 DISASSEMBLY.................................................................................1066 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES...................................................1087 ASSEMBLY....................................................................................1092 INSTALLATION................................................................................1120 SECTION 303-01B Engine — 4.6L(2V)...............................................................1130 SPECIFICATIONS..............................................................................1130 DESCRIPTION AND OPERATION...................................................................1136 DIAGNOSIS AND TESTING.......................................................................1145 IN-VEHICLE REPAIR...........................................................................1146 Intake Manifold.........................................................................1146 Valve Cover RH..........................................................................1166 Valve Cover LH..........................................................................1169 Crankshaft Pulley.......................................................................1172 Crankshaft Front Oil Seal...............................................................1175 Engine Front Cover......................................................................1178 Timing Drive Components.................................................................1187 Valve Seals.............................................................................1200 Hydraulic Lash Adjuster.................................................................1202 Camshaft Roller Follower................................................................1203 Camshaft................................................................................1206 Exhaust Manifold RH.....................................................................1208 Exhaust Manifold LH.....................................................................1211 Oil Filter Adapter......................................................................1214 Oil Level Indicator and Tube............................................................1217 Oil Pan.................................................................................1219 Flywheel................................................................................1228 Flexplate...............................................................................1230 Crankshaft Rear Oil Seal................................................................1232 Engine Mount RH.........................................................................1235 Engine Mount LH.........................................................................1238 REMOVAL.....................................................................................1241 Cylinder Heads..........................................................................1241 Engine..................................................................................1262 DISASSEMBLY.................................................................................1274 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES...................................................1298 ASSEMBLY....................................................................................1305 INSTALLATION................................................................................1341 Cylinder Heads..........................................................................1341 Engine..................................................................................1366 SECTION 303-01C Engine — Cobra 4.6L (4V)........................................................1379 SPECIFICATIONS..............................................................................1379 DESCRIPTION AND OPERATION...................................................................1385 DIAGNOSIS AND TESTING.......................................................................1401 IN-VEHICLE REPAIR...........................................................................1402 Lower Intake Manifold...................................................................1402 Valve Cover RH..........................................................................1409 Valve Cover LH..........................................................................1414 Crankshaft Pulley.......................................................................1420 Crankshaft Pulley —Auxiliary............................................................1423 Crankshaft Front Seal...................................................................1427 Engine Front Cover......................................................................1430 Timing Drive Components.................................................................1445 Hydraulic Lash Adjusters................................................................1452 Camshaft Roller Follower................................................................1453 Camshaft................................................................................1455 Exhaust Manifold RH.....................................................................1462 Exhaust Manifold LH.....................................................................1464 Oil Filter Adapter......................................................................1467 Oil Level Indicator and Tube............................................................1470 Oil Pan.................................................................................1472 Flywheel................................................................................1483 Crankshaft Rear Seal with Retainer Plate................................................1484 Engine Mount RH.........................................................................1487 Engine Mount LH.........................................................................1490 REMOVAL.....................................................................................1493 DISASSEMBLY.................................................................................1510 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES...................................................1533 Cylinder Head...........................................................................1533 Piston..................................................................................1544 Intake Manifold Assembly................................................................1547 ASSEMBLY....................................................................................1550 INSTALLATION................................................................................1585 SECTION 303-01D Engine — Mach 14.6L(4V..........................................................1602 SPECIFICATIONS..............................................................................1602 DESCRIPTION AND OPERATION...................................................................1608 DIAGNOSIS AND TESTING.......................................................................1623 IN-VEHICLE REPAIR...........................................................................1624 Intake Manifold —Upper..................................................................1624 Intake Manifold —Lower..................................................................1631 Valve Cover RH..........................................................................1635 Valve Cover LH..........................................................................1644 Crankshaft Pulley.......................................................................1652 Crankshaft Front Oil Seal...............................................................1655 Engine Front Cover......................................................................1658 Timing Drive Components.................................................................1679 Valve —Springs, Retainer and Valve Stem Seal............................................1686 Hydraulic Lash Adjusters................................................................1691 Roller Followers........................................................................1692 Camshaft................................................................................1694 Exhaust Manifold RH.....................................................................1701 Exhaust Manifold LH.....................................................................1703 Oil Filter Adapter......................................................................1706 Oil Level Indicator and Tube............................................................1708 Oil Pan.................................................................................1710 Flexplate...............................................................................1721 Flywheel................................................................................1723 Crankshaft Rear Oil Seal................................................................1724 Engine Mount............................................................................1727 REMOVAL.....................................................................................1737 DISASSEMBLY.................................................................................1756 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES...................................................1777 ASSEMBLY....................................................................................1791 INSTALLATION................................................................................1821 SECTION 303-03A Engine Cooling..................................................................1839 SPECIFICATIONS..............................................................................1839 DESCRIPTION AND OPERATION...................................................................1841 DIAGNOSIS AND TESTING.......................................................................1844 GENERAL PROCEDURES..........................................................................1854 Cooling System Draining, Filling and Bleeding ..........................................1854 Engine and Radiator Flushing............................................................1861 Heater Core Backflushing................................................................1863 REMOVAL AND INSTALLATION....................................................................1865 Thermostat —3.8L........................................................................1865 Thermostat —4.6L(2V)....................................................................1868 Thermostat —4.6L(4V)....................................................................1870 Bypass Tube —3.8L.......................................................................1872 Bypass Tube —Cobra......................................................................1875 Bypass Tube —Mach I.....................................................................1877 Water Pump —3.8L........................................................................1880 Water Pump —4.6L(2V) and 4.6L(4V).......................................................1883 Radiator................................................................................1887 Cooling Fan Motor and Shroud............................................................1891 Water Bypass Hose —3.8L.................................................................1893 Degas Bottle —4.6L(2V) and 4.6L(4V).....................................................1894 SECTION 303-03B Supercharger Cooling............................................................1896 SPECIFICATIONS..............................................................................1896 DESCRIPTION AND OPERATION...................................................................1898 DIAGNOSIS AND TESTING.......................................................................1900 GENERAL PROCEDURES..........................................................................1907 REMOVAL AND INSTALLATION....................................................................1911 SECTION 303-04A Fuel Charging and Controls — 3.8L...............................................1917 SPECIFICATIONS..............................................................................1917 DESCRIPTION AND OPERATION...................................................................1918 DIAGNOSIS AND TESTING.......................................................................1920 GENERAL PROCEDURES..........................................................................1921 REMOVAL AND INSTALLATION....................................................................1922 SECTION 303-04B Fuel Charging and Controls — 4.6L (2V)..........................................1933 SPECIFICATIONS..............................................................................1933 DESCRIPTION AND OPERATION...................................................................1934 DIAGNOSIS AND TESTING.......................................................................1937 GENERAL PROCEDURES..........................................................................1938 REMOVAL AND INSTALLATION....................................................................1939 SECTION 303-04C Fuel Charging and Controls — Cobra 4.6L (4V)....................................1965 SPECIFICATIONS..............................................................................1965 DESCRIPTION AND OPERATION...................................................................1966 DIAGNOSIS AND TESTING.......................................................................1968 REMOVAL AND INSTALLATION....................................................................1969 SECTION 303-04D Fuel Charging and Controls — Mach 14.6L (4V.....................................1982 SPECIFICATIONS..............................................................................1982 DESCRIPTION AND OPERATION...................................................................1984 DIAGNOSIS AND TESTING.......................................................................1987 GENERAL PROCEDURES..........................................................................1988 REMOVAL AND INSTALLATION....................................................................1989 SECTION 303-05 Accessory Drive..................................................................2007 SPECIFICATIONS..............................................................................2007 DESCRIPTION AND OPERATION...................................................................2008 DIAGNOSIS AND TESTING.......................................................................2013 REMOVAL AND INSTALLATION....................................................................2017 Accessory Drive Belt —3.8L..............................................................2017 Accessory Drive Belt —4.6L (2V) and (4V)................................................2018 Supercharger Belt.......................................................................2020 Accessory Drive Belt Tensioner —3.8L....................................................2022 Accessory Drive Belt Tensioner —4.6L (2V) and (4V)......................................2023 Supercharger Belt Tensioner.............................................................2026 Accessory Drive Belt Idler Pulley —3.8L.................................................2028 Accessory Drive Belt Idler Pulley —4.6L (2V) and (4V)...................................2029 Supercharger Belt Idler Pulley..........................................................2032 SECTION 303-06 Starting System..................................................................2034 SPECIFICATIONS..............................................................................2034 DESCRIPTION AND OPERATION...................................................................2035 DIAGNOSIS AND TESTING.......................................................................2037 GENERAL PROCEDURES..........................................................................2048 REMOVAL AND INSTALLATION....................................................................2050 SECTION 303-07A Engine Ignition — 3.8L..........................................................2057 SPECIFICATIONS..............................................................................2057 DESCRIPTION AND OPERATION...................................................................2058 DIAGNOSIS AND TESTING.......................................................................2060 REMOVAL AND INSTALLATION....................................................................2061 SECTION 303-07B Engine Ignition — 4.6L (2V).....................................................2070 SPECIFICATIONS..............................................................................2070 DESCRIPTION AND OPERATION...................................................................2071 DIAGNOSIS AND TESTING.......................................................................2073 REMOVAL AND INSTALLATION....................................................................2074 SECTION 303-07C Engine Ignition — 4.6L (4V).....................................................2080 SPECIFICATIONS..............................................................................2080 DESCRIPTION AND OPERATION...................................................................2081 DIAGNOSIS AND TESTING.......................................................................2083 REMOVAL AND INSTALLATION....................................................................2084 SECTION 303-08 Engine Emission Control..........................................................2089 SPECIFICATIONS..............................................................................2089 DESCRIPTION AND OPERATION...................................................................2090 DIAGNOSIS AND TESTING.......................................................................2093 REMOVAL AND INSTALLATION....................................................................2094 Exhaust Gas Recirculation (EGR) Valve...................................................2094 Exhaust Gas Recirculation (EGR) Valve —Cobra............................................2096 Exhaust Gas Recirculation (EGR) Valve —Mach I...........................................2100 Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube..........................2102 Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube —Cobra...................2104 Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube —Mach I..................2105 Differential Pressure Feedback Exhaust Gas Recirculation (EGR) System...................2107 Exhaust Gas Recirculation (EGR) Vacuum Regulator Solenoid...............................2108 Positive Crankcase Ventilation (PCV) Hose...............................................2109 SECTION 303-12 Intake Air Distribution and Filtering............................................2111 SPECIFICATIONS..............................................................................2111 DESCRIPTION AND OPERATION...................................................................2112 DIAGNOSIS AND TESTING.......................................................................2115 REMOVAL AND INSTALLATION....................................................................2116 Air Cleaner Outlet Pipe —3.8L...........................................................2116 Air Cleaner Outlet Pipe —4.6L (2V)......................................................2117 Air Cleaner Outlet Pipe —4.6L (4V)......................................................2119 Air Cleaner —3.8L.......................................................................2121 Air Cleaner —4.6L (2V) and 4.6L (4V)....................................................2123 Air Cleaner Element —3.8L...............................................................2125 Air Cleaner Element —4.6L (2V)..........................................................2127 Air Cleaner Element —4.6L (4V)..........................................................2129 Air Intake Scoop........................................................................2130 Air Intake Scoop Bracket................................................................2132 Charge Air Cooler.......................................................................2134 SECTION 303-13 Evaporative Emissions............................................................2144 SPECIFICATIONS..............................................................................2144 DESCRIPTION AND OPERATION...................................................................2145 DIAGNOSIS AND TESTING.......................................................................2148 GENERAL PROCEDURES..........................................................................2173 REMOVAL AND INSTALLATION....................................................................2179 Evaporative Emission Canister...........................................................2179 Evaporative Emission Canister Purge Valve...............................................2182 Fuel Vapor Vent Valve...................................................................2185 Fuel Vapor Control Tube Assembly Valve..................................................2186 Fuel Tank Pressure Sensor...............................................................2188 Evaporative Emission Test Port..........................................................2189 Evaporative Emission Canister Vent Solenoid.............................................2191 SECTION 303-14 Electronic Engine Controls.......................................................2192 SPECIFICATIONS..............................................................................2192 DESCRIPTION AND OPERATION...................................................................2194 DIAGNOSIS AND TESTING.......................................................................2199 REMOVAL AND INSTALLATION....................................................................2200 Temperature and Manifold Absolute Pressure (T-MAP) Sensor —Cobra........................2200 Camshaft Position (CMP) Sensor —3.8L....................................................2202 Camshaft Position (CMP) Sensor —4.6L....................................................2203 Intake Manifold Runner Control (IMRC) Actuator —3.8L....................................2205 Crankshaft Position (CKP) Sensor —3.8L..................................................2207 Crankshaft Position (CKP) Sensor —4.6L..................................................2208 Powertrain Control Module (PCM).........................................................2209 Throttle Position (TP) Sensor...........................................................2212 Throttle Position (TP) Sensor —Cobra....................................................2214 Throttle Position (TP) Sensor —Mach I...................................................2216 Idle Air Control (IAC) Valve —3.8L......................................................2218 Idle Air Control (IAC) Valve —4.6L (2V).................................................2220 Idle Air Control (IAC) Valve —Cobra.....................................................2222 Idle Air Control (IAC) Valve —Mach I....................................................2224 Cylinder Head Temperature (CHT) Sensor —3.8L............................................2226 Engine Coolant Temperature (ECT) Sensor —4.6L (2V)......................................2228 Engine Coolant Temperature (ECT) Sensor —Cobra..........................................2230 Engine Coolant Temperature (ECT) Sensor —Mach I.........................................2232 Mass Air Flow (MAF) Sensor —3.8L........................................................2234 Mass Air Flow (MAF) Sensor —4.6L (2V)...................................................2236 Mass Air Flow (MAF) Sensor —Cobra.......................................................2238 Mass Air Flow (MAF) Sensor —Mach I......................................................2241 Heated Oxygen Sensor (HO2S).............................................................2243 Catalyst Monitor Sensor.................................................................2245 Clutch Pedal Position (CPP) Switch......................................................2247 Fuel Pressure Sensor....................................................................2249 Supercharger Bypass Vacuum Solenoid.....................................................2251 Supercharger Bypass Vacuum Solenoid —Actuator...........................................2252 07 - Automatic Transmission.........................................................................2258 SECTION 307-01 Automatic Transaxle- Transmission................................................2258 SPECIFICATIONS..............................................................................2258 DESCRIPTION AND OPERATION...................................................................2264 Transmission Description................................................................2264 Identification Tags.....................................................................2265 Range Selection.........................................................................2266 Shift Patterns..........................................................................2268 Disassembled Views......................................................................2269 Bushings, Bearing and Thrust Washer Locator.............................................2277 Seals, Rings and Gasket Locator.........................................................2279 Main Components and Functions...........................................................2282 Torque Converter........................................................................2284 Geartrain...............................................................................2286 Apply Components........................................................................2288 Hydraulic System........................................................................2293 Transmission Electronic Control System..................................................2297 DIAGNOSIS AND TESTING.......................................................................2301 Diagnostic Strategy.....................................................................2301 Diagnostic Flow Chart...................................................................2303 Preliminary Inspection..................................................................2305 Road Testing Vehicle....................................................................2308 Shift Point Road Test...................................................................2309 Torque Converter Diagnosis..............................................................2312 Visual Inspection.......................................................................2316 Diagnostics.............................................................................2318 Output State Control (OSC) Mode.........................................................2321 Transmission Drive Cycle Test...........................................................2330 Diagnostic Trouble Code Charts..........................................................2332 Transmission Connector Layouts..........................................................2340 Pinpoint Tests — OSC Equipped Vehicles..................................................2344 Special Testing Procedures..............................................................2366 Leakage Inspection......................................................................2373 Transmission Fluid Cooler...............................................................2378 Diagnosis By Symptom....................................................................2380 GENERAL PROCEDURES..........................................................................2411 IN-VEHICLE REPAIR...........................................................................2419 Fluid Pan, Gasket and Filter............................................................2419 Transmission Filler Tube................................................................2424 Main Control Valve Body.................................................................2426 Extension Housing Seal and Gasket.......................................................2433 Electronic Pressure Control (EPC) Solenoid..............................................2438 Manual Control Lever Shaft and Seal.....................................................2441 Digital Transmission Range (TR) Sensor..................................................2447 Reverse Servo Assembly..................................................................2451 Overdrive Servo.........................................................................2456 1-2 Accumulator.........................................................................2458 2-3 Accumulator.........................................................................2460 Transmission Support Crossmember........................................................2462 REMOVAL.....................................................................................2464 DISASSEMBLY.................................................................................2471 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES...................................................2487 Main Control Valve Body.................................................................2487 Pump and Intermediate Clutch Piston.....................................................2495 Intermediate One-Way Clutch.............................................................2502 Reverse Clutch..........................................................................2504 Forward Clutch Cylinder.................................................................2513 Planetary Gear Support Assembly and Planetary One-Way Clutch............................2522 Reverse Sun Gear........................................................................2524 Output Shaft and Direct Clutch Cylinder.................................................2526 Torque Converter........................................................................2537 Torque Converter Cleaning And Inspection................................................2538 Torque Converter Flushing...............................................................2540 Torque Converter Leak Check.............................................................2541 Torque Converter Impeller to Pump Stator Interference Check.............................2544 Torque Converter End Play Check.........................................................2546 Torque Converter One-Way Clutch Check...................................................2548 Torque Converter Turbine to Pump Stator Interference Check..............................2550 ASSEMBLY....................................................................................2552 INSTALLATION................................................................................2577 SECTION 307-02 Transaxle- Transmission Cooling..................................................2584 SPECIFICATIONS..............................................................................2584 DESCRIPTION AND OPERATION...................................................................2585 DIAGNOSIS AND TESTING.......................................................................2587 REMOVAL AND INSTALLATION....................................................................2589 SECTION 307-05 Automatic Transaxle- Transmission External Controls..............................2592 SPECIFICATIONS..............................................................................2592 DESCRIPTION AND OPERATION...................................................................2593 DIAGNOSIS AND TESTING.......................................................................2594 GENERAL PROCEDURES..........................................................................2600 REMOVAL AND INSTALLATION....................................................................2602 Brake Shift Interlock Actuator..........................................................2602 Cable and Bracket.......................................................................2607 Selector Lever..........................................................................2610 Transmission Control Switch.............................................................2614 Bezel...................................................................................2617 Bulb....................................................................................2620 Knob....................................................................................2622 08 - Manual Transmission. Clutch and Transfer Case..................................................2625 SECTION 308-00 Manual Transrnissi-Transaxle anc Clutch -General Information.....................2625 SPECIFICATIONS..............................................................................2625 DESCRIPTION AND OPERATION...................................................................2626 DIAGNOSIS AND TESTING.......................................................................2630 GENERAL PROCEDURES..........................................................................2645 REMOVAL AND INSTALLATION....................................................................2653 SECTION 308-01 Clutch...........................................................................2656 SPECIFICATIONS..............................................................................2656 DESCRIPTION AND OPERATION...................................................................2658 DIAGNOSIS AND TESTING.......................................................................2659 REMOVAL AND INSTALLATION....................................................................2660 SECTION 308-02 Clutch Controls..................................................................2671 SPECIFICATIONS..............................................................................2671 DESCRIPTION AND OPERATION...................................................................2673 DIAGNOSIS AND TESTING.......................................................................2675 REMOVAL AND INSTALLATION....................................................................2676 SECTION 308-03A Manual TransaxleTransmission — T5OD.............................................2687 SPECIFICATIONS..............................................................................2687 DESCRIPTION AND OPERATION...................................................................2689 DIAGNOSIS AND TESTING.......................................................................2694 IN-VEHICLE REPAIR...........................................................................2695 REMOVAL.....................................................................................2702 DISASSEMBLY.................................................................................2708 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES ..................................................2719 Selector Plate..........................................................................2719 Input Shaft and Bearing.................................................................2723 Output Shaft............................................................................2726 Countershaft Bearing....................................................................2736 Synchronizers...........................................................................2739 ASSEMBLY....................................................................................2741 INSTALLATION................................................................................2755 SECTION 308-03B Manual TransaxleTransmission — TR3650...........................................2756 SPECIFICATIONS..............................................................................2756 DESCRIPTION AND OPERATION...................................................................2758 DIAGNOSIS AND TESTING.......................................................................2765 GENERAL PROCEDURES..........................................................................2766 IN-VEHICLE REPAIR...........................................................................2769 REMOVAL.....................................................................................2776 DISASSEMBLY.................................................................................2781 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES...................................................2796 Input Shaft and Bearing.................................................................2796 Output Shaft............................................................................2799 Countershaft Bearing....................................................................2816 Synchronizers...........................................................................2818 Gearshift Rail Bushing..................................................................2820 Gearshift Rail and Fork.................................................................2822 ASSEMBLY....................................................................................2824 INSTALLATION................................................................................2843 SECTION 308-03C Manual TransaxleTransmission — T56..............................................2844 SPECIFICATIONS..............................................................................2844 DESCRIPTION AND OPERATION...................................................................2846 DIAGNOSIS AND TESTING.......................................................................2848 GENERAL PROCEDURES..........................................................................2849 REMOVAL.....................................................................................2851 DISASSEMBLY.................................................................................2856 DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES...................................................2869 Input Shaft and Bearing.................................................................2869 Output Shaft............................................................................2873 Countershaft............................................................................2885 Synchronizers...........................................................................2893 Gearshift Rail and Fork.................................................................2895 Extension Housing.......................................................................2898 Transmission Case.......................................................................2904 ASSEMBLY....................................................................................2908 INSTALLATION................................................................................2926 09 - Exhaust System - SECTION 309-00 Exhaust System.................................................2931 SPECIFICATIONS..................................................................................2931 DESCRIPTION AND OPERATION.......................................................................2932 DIAGNOSIS AND TESTING...........................................................................2935 REMOVAL AND INSTALLATION........................................................................2937 Muffler —3.8L...............................................................................2937 Muffler —4.6L (2V)..........................................................................2940 Muffler —4.6L (4V)..........................................................................2943 Dual Converter Y-Pipe —3.8L.................................................................2946 Dual Converter H-Pipe —4.6L (2V and 4V).....................................................2951 10 - Fuel System....................................................................................2955 SECTION 310-00 Fuel System - General Information................................................2955 SPECIFICATIONS..............................................................................2955 DESCRIPTION AND OPERATION...................................................................2956 DIAGNOSIS AND TESTING.......................................................................2958 GENERAL PROCEDURES..........................................................................2959 Pressure Relief.........................................................................2959 Fuel Tank Draining......................................................................2961 Spring Lock Couplings...................................................................2963 Fuel Line Fittings —Push Connect........................................................2966 Fittings —R-Clip........................................................................2969 Fittings —Vapor Tube....................................................................2972 SECTION 310-01 Fuel Tank and Lines..............................................................2974 SPECIFICATIONS..............................................................................2974 DESCRIPTION AND OPERATION...................................................................2975 DIAGNOSIS AND TESTING.......................................................................2976 REMOVAL AND INSTALLATION....................................................................2977 Fuel Tank...............................................................................2977 Support Straps..........................................................................2982 Fuel Pump Module........................................................................2984 Fuel Tank Filler Pipe...................................................................2986 Fuel Filter.............................................................................2987 Inertia Fuel Shutoff (IFS) Switch.......................................................2989 SECTION 310-02 Acceleration Control.............................................................2990 DESCRIPTION AND OPERATION...................................................................2990 DIAGNOSIS AND TESTING.......................................................................2992 REMOVAL AND INSTALLATION....................................................................2994 Accelerator Pedal and Shaft.............................................................2994 Accelerator Cable —3.8L.................................................................2996 Accelerator Cable —4.6L (2V)............................................................2998 Accelerator Cable —Supercharged Engine..................................................3000 Accelerator Cable Bracket —3.8L.........................................................3002 Accelerator Cable Bracket —4.6L (2V)....................................................3004 Accelerator Cable Bracket —Supercharged Engine..........................................3006 SPECIFICATIONS..............................................................................3008 SECTION 310-03 Speed Control....................................................................3009 SPECIFICATIONS..............................................................................3009 DESCRIPTION AND OPERATION...................................................................3010 DIAGNOSIS AND TESTING.......................................................................3011 GENERAL PROCEDURES..........................................................................3024 REMOVAL AND INSTALLATION....................................................................3025 Actuator Cable —Speed Control...........................................................3025 Actuator Cable —Speed Control-Cobra.....................................................3027 Actuator —Speed Control Servo...........................................................3029 Switch —Deactivator.....................................................................3032 Switch —Speed Control Actuator..........................................................3034 4 - Electrical..........................................................................................3037 12 - Climate Control System.........................................................................3037 SECTION 412-00 Climate Control System - General Information.....................................3037 SPECIFICATIONS..............................................................................3037 DESCRIPTION AND OPERATION...................................................................3039 DIAGNOSIS AND TESTING.......................................................................3050 GENERAL PROCEDURES..........................................................................3091 Air Conditioning (A-C) System Check — Retail Procedure..................................3091 Spring Lock Coupling....................................................................3093 Heater Hose Coupling....................................................................3099 Air Conditioning Line (Peanut) Fitting..................................................3102 Refrigerant System Tests................................................................3105 Air Conditioning (A-C) Clutch Air Gap Adjustment........................................3109 Manifold Gauge Set Connection...........................................................3110 Electronic Leak Detection...............................................................3113 Tracer Dye Leak Detection...............................................................3115 Air Conditioning (A-C) System Flushing..................................................3117 Air Conditioning (A-C) System Recovery, Evacuation and Charging.........................3120 Refrigerant System Filtering Following Air Conditioning (A-C) Component Installation....3123 Refrigerant Oil Adding..................................................................3125 Inspection and Assembly Requirements —Following an AC Compressor Failure................3127 Refrigerant Identification Testing......................................................3129 Contaminated Refrigerant Handling.......................................................3131 Vacuum Hose Repair —Mini-Tube...........................................................3133 SECTION 412-01 Air Distribution and Filtering...................................................3135 SPECIFICATIONS..............................................................................3135 DESCRIPTION AND OPERATION...................................................................3136 DIAGNOSIS AND TESTING.......................................................................3139 REMOVAL AND INSTALLATION....................................................................3140 Register —LH............................................................................3140 Register —Center........................................................................3143 Nozzle —LH Demister and Hose............................................................3144 Nozzle —RH Demister and Hose............................................................3145 Duct —Floor.............................................................................3146 Duct —Defroster.........................................................................3147 Duct —RH Instrument Panel Register......................................................3148 Plenum Chamber..........................................................................3150 Door —Air Inlet Duct....................................................................3153 SECTION 412-02 Heating and Ventilation..........................................................3155 SPECIFICATIONS..............................................................................3155 DESCRIPTION AND OPERATION...................................................................3156 DIAGNOSIS AND TESTING.......................................................................3158 REMOVAL AND INSTALLATION....................................................................3159 DISASSEMBLY AND ASSEMBLY....................................................................3168 SECTION 412-03 Air Conditioning.................................................................3172 SPECIFICATIONS..............................................................................3172 DESCRIPTION AND OPERATION...................................................................3174 DIAGNOSIS AND TESTING.......................................................................3184 REMOVAL AND INSTALLATION....................................................................3185 Air Conditioning (AC) Compressor —3.8L..................................................3185 Air Conditioning (AC) Compressor —4.6L..................................................3189 Air Conditioning (AC) Compressor Bracket —3.8L..........................................3192 Clutch And Clutch Field Coil............................................................3193 Air Conditioning (AC) Compressor Shaft Seal.............................................3198 Evaporator Core.........................................................................3205 Suction Accumulator.....................................................................3206 Air Conditioning (AC) Pressure Relief Valve —3.8L.......................................3209 Air Conditioning (AC) Pressure Relief Valve —4.6L.......................................3211 Condenser Core..........................................................................3213 Compressor Manifold and Tube Assembly —3.8L.............................................3218 Compressor Manifold and Tube Assembly —4.6L.............................................3222 Suction Accumulator to Compressor Line —4.6L............................................3225 Compressor to Condenser Discharge Line —4.6L............................................3227 Condenser to Evaporator Line............................................................3230 SECTION 412-04 Control Components...............................................................3233 DESCRIPTION AND OPERATION...................................................................3233 DIAGNOSIS AND TESTING.......................................................................3237 REMOVAL AND INSTALLATION....................................................................3238 Control Assembly........................................................................3238 Switch..................................................................................3242 Actuator —Temperature Control Cable.....................................................3244 Resistor................................................................................3245 Vacuum Control Motor —Air Inlet Duct Door...............................................3247 Vacuum Control Motor —Air Damper Door...................................................3249 Vacuum Control Motor —Windshield- Defroster Door........................................3250 Vacuum Reservoir Tank...................................................................3251 13 - Instrumentation and Warning Systems............................................................3252 SECTION 413-00 Instrument Cluster and Panel Illumination........................................3252 DESCRIPTION AND OPERATION...................................................................3252 DIAGNOSIS AND TESTING.......................................................................3253 REMOVAL AND INSTALLATION....................................................................3258 SECTION 413-01 Instrument Cluster...............................................................3259 DESCRIPTION AND OPERATION...................................................................3259 DIAGNOSIS AND TESTING.......................................................................3263 REMOVAL AND INSTALLATION....................................................................3304 SECTION 413-06 Horn.............................................................................3309 SPECIFICATIONS..............................................................................3309 DESCRIPTION AND OPERATION...................................................................3310 DIAGNOSIS AND TESTING.......................................................................3311 REMOVAL AND INSTALLATION....................................................................3316 SECTION 413-09 Warning Devices..................................................................3318 DESCRIPTION AND OPERATION...................................................................3318 DIAGNOSIS AND TESTING.......................................................................3319 GENERAL PROCEDURES..........................................................................3339 REMOVAL AND INSTALLATION....................................................................3341 14 - Battery and Charging System....................................................................3345 SECTION 414-00 Charging System - General Information............................................3345 SPECIFICATIONS..............................................................................3345 DESCRIPTION AND OPERATION...................................................................3346 DIAGNOSIS AND TESTING.......................................................................3348 SECTION 414-01 Battery, Mounting and Cables.....................................................3362 SPECIFICATIONS..............................................................................3362 DESCRIPTION AND OPERATION...................................................................3364 DIAGNOSIS AND TESTING.......................................................................3366 GENERAL PROCEDURES..........................................................................3368 REMOVAL AND INSTALLATION....................................................................3370 Battery.................................................................................3370 Battery Tray............................................................................3373 Battery Cables..........................................................................3375 SECTION 414-02 Generator and Regulator..........................................................3381 SPECIFICATIONS..............................................................................3381 DESCRIPTION AND OPERATION...................................................................3383 DIAGNOSIS AND TESTING.......................................................................3384 REMOVAL AND INSTALLATION....................................................................3385 15 - Audio Systems..................................................................................3391 SECTION 415-00 Entertainment System - General Information- DIAGNOSIS AND TESTING................3391 SECTION 415-01 Audio Unit.......................................................................3415 SPECIFICATIONS..............................................................................3415 DESCRIPTION AND OPERATION...................................................................3416 DIAGNOSIS AND TESTING.......................................................................3417 REMOVAL AND INSTALLATION....................................................................3418 Audio Unit..............................................................................3418 Subwoofer Amplifier —Convertible........................................................3419 Subwoofer Amplifier —Coupe..............................................................3421 Subwoofer Amplifier —Mach 1000..........................................................3422 SECTION 415-02 Antenna..........................................................................3424 SPECIFICATIONS..............................................................................3424 DESCRIPTION AND OPERATION...................................................................3425 DIAGNOSIS AND TESTING.......................................................................3426 REMOVAL AND INSTALLATION....................................................................3427 SECTION 415-03 Speakers.........................................................................3431 SPECIFICATIONS..............................................................................3431 DESCRIPTION AND OPERATION...................................................................3432 DIAGNOSIS AND TESTING.......................................................................3433 REMOVAL AND INSTALLATION....................................................................3434 Door Speaker —Upper.....................................................................3434 Door Speaker —Lower.....................................................................3436 Speaker —Package Tray (Coupe)...........................................................3437 Subwoofer Speaker —Coupe................................................................3438 Subwoofer Speaker —Convertible..........................................................3440 Quarter Panel Speaker...................................................................3442 17 - Lighting.......................................................................................3443 SECTION 417-01 Exterior Lighting................................................................3443 SPECIFICATIONS..............................................................................3443 DESCRIPTION AND OPERATION...................................................................3444 DIAGNOSIS AND TESTING.......................................................................3445 Headlamps...............................................................................3445 Stoplamps...............................................................................3453 Turn Signal and Hazard Lamps............................................................3458 Parking, Rear and License Lamps.........................................................3462 Fog Lamps...............................................................................3465 Reversing Lamps.........................................................................3471 GENERAL PROCEDURES..........................................................................3475 REMOVAL AND INSTALLATION....................................................................3479 Bulb —Headlamp..........................................................................3479 Lamp Assembly —Headlamp.................................................................3481 Lamp Assembly —Fog Lamp (GT)............................................................3483 Lamp Assembly —Fog Lamp (Cobra).........................................................3485 Lamp Assembly —Rear.....................................................................3486 Lamp Switch —Headlamp...................................................................3488 Lamp Switch —Brake Pedal Position (BPP).................................................3490 SECTION 417-02 Interior Lighting................................................................3492 DESCRIPTION AND OPERATION...................................................................3492 DIAGNOSIS AND TESTING.......................................................................3493 REMOVAL AND INSTALLATION....................................................................3509 SECTION 417-04 Daytime Running Lamps (DRL)......................................................3511 SPECIFICATIONS..............................................................................3511 DESCRIPTION AND OPERATION...................................................................3512 DIAGNOSIS AND TESTING.......................................................................3513 REMOVAL AND INSTALLATION....................................................................3519 18 - Electrical Distribution........................................................................3521 SECTION 418-00 Module Communications Network....................................................3521 SPECIFICATIONS..............................................................................3521 DESCRIPTION AND OPERATION...................................................................3522 DIAGNOSIS AND TESTING.......................................................................3524 GENERAL PROCEDURES..........................................................................3545 SECTION 418-01 Module Configuration- DIAGNOSIS AND TESTING......................................3548 19 - Electronic Feature Group.......................................................................3551 SECTION 419-01 Anti-Theft — PATS................................................................3551 SPECIFICATIONS..............................................................................3551 DESCRIPTION AND OPERATION...................................................................3552 DIAGNOSIS AND TESTING.......................................................................3554 GENERAL PROCEDURES..........................................................................3572 Key Programming —Erase All Key Codes and Program Two Keys...............................3572 Key Programming —Program a Key Using Two Programmed Keys................................3574 Key Programming —Enable-Disable Spare Key Programming...................................3576 Key Programming —Additional Key With One Programmed Key.................................3578 Security Access —Procedure..............................................................3580 REMOVAL AND INSTALLATION....................................................................3582 SECTION 419-10 Multifunction Electronic Modules.................................................3586 SPECIFICATIONS..............................................................................3586 DESCRIPTION AND OPERATION...................................................................3587 DIAGNOSIS AND TESTING.......................................................................3588 REMOVAL AND INSTALLATION....................................................................3589 5 - Body and Paint......................................................................................3591 01 - Body...........................................................................................3591 SECTION 501-00 Body System - General Information................................................3591 SPECIFICATIONS..............................................................................3591 DESCRIPTION AND OPERATION...................................................................3592 DIAGNOSIS AND TESTING.......................................................................3596 SECTION 501-02 Front End Body Panels............................................................3598 SPECIFICATIONS..............................................................................3598 DESCRIPTION AND OPERATION...................................................................3599 REMOVAL AND INSTALLATION....................................................................3600 SECTION 501-03 Body Closures....................................................................3604 SPECIFICATIONS..............................................................................3604 DESCRIPTION AND OPERATION...................................................................3606 GENERAL PROCEDURES..........................................................................3607 REMOVAL AND INSTALLATION....................................................................3614 SECTION 501-05 Interior Trim and Ornamentation..................................................3619 SPECIFICATIONS..............................................................................3619 DESCRIPTION AND OPERATION...................................................................3620 REMOVAL AND INSTALLATION....................................................................3621 Trim Panel —Door........................................................................3621 Trim Panel —Quarter, Coupe..............................................................3624 Trim Panel —Quarter, Convertible........................................................3626 Trim Panel —Upper Quarter...............................................................3629 Trim Panel —Package Tray................................................................3632 Headliner...............................................................................3635 SECTION 501-08 Exterior Trim and Ornamentation..................................................3638 SPECIFICATIONS..............................................................................3638 DESCRIPTION AND OPERATION...................................................................3639 REMOVAL AND INSTALLATION....................................................................3640 SECTION 501-09 Rear View Mirrors................................................................3648 SPECIFICATIONS..............................................................................3648 DESCRIPTION AND OPERATION...................................................................3649 DIAGNOSIS AND TESTING.......................................................................3650 REMOVAL AND INSTALLATION....................................................................3658 SECTION 501-10 Seating..........................................................................3663 SPECIFICATIONS .............................................................................3663 DESCRIPTION AND OPERATION...................................................................3664 DIAGNOSIS AND TESTING.......................................................................3667 REMOVAL AND INSTALLATION....................................................................3682 Switch —Seat Regulator Control..........................................................3682 Lumbar Control Switch...................................................................3684 Front Seat Backrest.....................................................................3687 Lumbar Assembly.........................................................................3689 Seat —Front Power.......................................................................3692 Seat Track..............................................................................3694 Lumbar Motor............................................................................3696 Latch —Front Seat Backrest..............................................................3699 DISASSEMBLY AND ASSEMBLY....................................................................3702 Front Seat Cushion......................................................................3702 Front Seat Backrest.....................................................................3706 SECTION 501-11 Glass, Frames and Mechanisms.....................................................3710 SPECIFICATIONS..............................................................................3710 DESCRIPTION AND OPERATION...................................................................3712 DIAGNOSIS AND TESTING.......................................................................3714 GENERAL PROCEDURES..........................................................................3746 Heated Window Grid Wire Repair..........................................................3746 Lead Terminal Repair....................................................................3749 Door Window Glass Adjustment —Height Stop Adjustment....................................3752 Door Window Glass Adjustment —Stabilizer................................................3754 Rear Quarter Window Glass Adjustment —Convertible.......................................3756 REMOVAL AND INSTALLATION....................................................................3757 Switch —Window Regulator Control........................................................3757 Rear Window Defrost Switch..............................................................3759 Rear Window Glass.......................................................................3760 Window Glass —Door......................................................................3764 Window Glass —Quarter...................................................................3766 Window Glass —Quarter, Convertible......................................................3768 Motor —Window Regulator.................................................................3771 Motor —Window Regulator, Quarter........................................................3773 Window Regulator —Power.................................................................3775 Window Regulator —Quarter...............................................................3777 Windshield Glass........................................................................3779 Door Glass Run Retainer.................................................................3789 SECTION 501-12 Instrument Panel and Console.....................................................3790 SPECIFICATIONS..............................................................................3790 DESCRIPTION AND OPERATION...................................................................3791 REMOVAL AND INSTALLATION....................................................................3793 SECTION 501-14A Handles, Locks, Latches and Mechanisms..........................................3812 SPECIFICATIONS..............................................................................3812 DESCRIPTION AND OPERATION...................................................................3814 DIAGNOSIS AND TESTING.......................................................................3816 REMOVAL AND INSTALLATION....................................................................3817 Latch —Door.............................................................................3817 Latch —Luggage Compartment Lid..........................................................3820 Handle —Exterior Door...................................................................3822 Handle —Interior Door...................................................................3824 Ignition Lock Cylinder —Functional......................................................3826 Ignition Lock Cylinder —Non-Functional..................................................3828 Lock Cylinder —Door.....................................................................3831 Lock Cylinder —Luggage Compartment Lid..................................................3833 Push Button Rod —Door...................................................................3835 Actuator —Door Lock.....................................................................3836 Switch —Door Ajar Switch................................................................3838 Switch —Door Lock.......................................................................3839 SECTION 501-14B Keyless Entry-Computer Operated Locks...........................................3841 DESCRIPTION AND OPERATION...................................................................3841 DIAGNOSIS AND TESTING.......................................................................3842 GENERAL PROCEDURES..........................................................................3863 REMOVAL AND INSTALLATION....................................................................3864 SECTION 501-16 Wipers and Washers...............................................................3866 SPECIFICATIONS..............................................................................3866 DESCRIPTION AND OPERATION...................................................................3867 DIAGNOSIS AND TESTING.......................................................................3868 GENERAL PROCEDURES..........................................................................3888 REMOVAL AND INSTALLATION....................................................................3890 Pivot Arm...............................................................................3890 Mounting Arm and Pivot Shaft............................................................3891 Motor —Windshield Wiper.................................................................3894 Washer Pump.............................................................................3897 Reservoir...............................................................................3899 Module —Generic Electronic (GEM)........................................................3901 Switch —Multi-Function..................................................................3902 SECTION 501-18 Convertible Top..................................................................3903 SPECIFICATIONS..............................................................................3903 DESCRIPTION AND OPERATION...................................................................3905 DIAGNOSIS AND TESTING.......................................................................3907 GENERAL PROCEDURES..........................................................................3917 REMOVAL AND INSTALLATION....................................................................3926 Convertible Top Assembly —Side Rail, Folding Top........................................3926 Convertible Top Assembly —Rear Window Glass.............................................3938 Convertible Top Material................................................................3944 Stay Pad —Convertible Top...............................................................3957 Convertible Top Switch..................................................................3960 Hydraulic System, Lift Cylinder and Motor...............................................3961 SECTION 501-19 Bumpers..........................................................................3967 SPECIFICATIONS..............................................................................3967 DESCRIPTION AND OPERATION...................................................................3968 REMOVAL AND INSTALLATION....................................................................3969 Front Bumper Cover......................................................................3969 Rear Bumper Cover.......................................................................3972 Front Bumper............................................................................3974 Rear Bumper.............................................................................3976 SECTION 501-20A Safety Belt System..............................................................3978 SPECIFICATIONS..............................................................................3978 DESCRIPTION AND OPERATION...................................................................3979 DIAGNOSIS AND TESTING.......................................................................3982 GENERAL PROCEDURES..........................................................................3986 Safety Belt Cleaning....................................................................3986 Safety Belt Maintenance.................................................................3987 Safety Belt With Anchor Plate Thread Damage.............................................3988 Replacement of the Weld Nut and Reinforcement...........................................3989 Safety Belt Procedure After a Collision.................................................3990 Safety Belt Tongue Rotated on Belt......................................................3991 REMOVAL AND INSTALLATION....................................................................3993 Retractor —Front Seat Safety Belt, Coupe................................................3993 Retractor —Front Seat Safety Belt, Convertible..........................................3997 Retractor —Rear Seat Safety Belt, Coupe.................................................3999 Retractor —Rear Seat Safety Belt, Convertible...........................................4002 Child Safety Seat Belt —Tether Anchor...................................................4005 Safety Belt Buckle —Front Seat..........................................................4007 Safety Belt Buckle —Rear Seat...........................................................4009 Child Safety Seat Tether Anchor —LATCH..................................................4011 SECTION 501-20B Supplemental Restraint System...................................................4012 SPECIFICATIONS..............................................................................4012 DESCRIPTION AND OPERATION...................................................................4013 DIAGNOSIS AND TESTING.......................................................................4017 Air Bag Supplemental Restraint System (SRS).............................................4017 Diagnostic Instructions — Air Bag Supplemental Restraint System (SRS)...................4023 Pinpoint Tests — Air Bag Supplemental Restraint System (SRS)............................4028 GENERAL PROCEDURES..........................................................................4074 Inspection and Repair After a Supplemental Restraint System (SRS) Deployment............4074 Air Bag Disposal —Deployed Air Bag......................................................4076 Air Bag Disposal —Undeployed Inoperative................................................4077 Air Bag Disposal —Driver, Undeployed, Scrapped Vehicle..................................4079 Air Bag Disposal —Passenger, Undeployed, Scrapped Vehicle...............................4082 Supplemental Restraint System (SRS) Deactivation and Reactivation.......................4085 Weld Nut Repair —J Nut, Restraints Control Module (RCM).................................4092 Weld Nut Repair —Missing Weld Nut, Restraints Control Module (RCM)......................4094 Weld Nut Repair —Stripped Weld Nut, Restraints Control Module (RCM).....................4096 REMOVAL AND INSTALLATION....................................................................4098 Restraints Control Module (RCM).........................................................4098 Driver Air Bag Module...................................................................4102 Passenger Air Bag Module................................................................4108 Clockspring.............................................................................4112 02 - Frame and Mounting.............................................................................4123 02 - Frame and Mounting - SECTION 502-00 Frame and Body Mounting................................4123 SPECIFICATIONS..............................................................................4123 DESCRIPTION AND OPERATION...................................................................4124 GENERAL PROCEDURES..........................................................................4125 REMOVAL AND INSTALLATION....................................................................4129 Front Subframe —3.8L Engine.............................................................4129 Front Subframe —4.6L (2V) Engine........................................................4134 Front Subframe —4.6L (4V) Engine........................................................4138 Rear Subframe...........................................................................4142 Subframe Support —Convertible...........................................................4144 6- Wiring Diagrams......................................................................................4146 Using Wiring Diagrams...............................................................................4146 2003 Ford Mustang...................................................................................4155 AIR CONDITIONING................................................................................4155 ANTI-LOCK BRAKES................................................................................4157 ANTI-THEFT......................................................................................4158 BODY CONTROL MODULES............................................................................4159 COMPUTER DATA LINES.............................................................................4160 COOLING FAN.....................................................................................4161 CRUISE CONTROL..................................................................................4164 DEFOGGERS.......................................................................................4165 ENGINE PERFORMANCE..............................................................................4166 EXTERIOR LIGHTS.................................................................................4177 GROUND DISTRIBUTION.............................................................................4179 HEADLIGHTS......................................................................................4181 HORN............................................................................................4183 INSTRUMENT CLUSTER..............................................................................4184 INTERIOR LIGHTS.................................................................................4185 POWER DISTRIBUTION..............................................................................4187 POWER DOOR LOCKS................................................................................4190 POWER MIRRORS...................................................................................4191 POWER SEATS.....................................................................................4191 Fig. 38: Power Seat CircuitPOWER TOP/SUNROOF....................................................4194 POWER WINDOWS...................................................................................4194 RADIO...........................................................................................4197 SHIFT INTERLOCK.................................................................................4203 STARTING/CHARGING...............................................................................4203 SUPPLEMENTAL RESTRAINTS.........................................................................4206 TRANSMISSION....................................................................................4206 TRUNK, TAILGATE, FUEL DOOR......................................................................4208 WARNING SYSTEMS.................................................................................4209 WIPER/WASHER....................................................................................4209 2003 Ford Mustang GT................................................................................4211 AIR CONDITIONING................................................................................4211 ANTI-LOCK BRAKES................................................................................4214 ANTI-THEFT......................................................................................4215 BODY CONTROL MODULES............................................................................4215 COMPUTER DATA LINES.............................................................................4216 COOLING FAN.....................................................................................4218 CRUISE CONTROL..................................................................................4220 DEFOGGERS.......................................................................................4221 ENGINE PERFORMANCE..............................................................................4222 EXTERIOR LIGHTS.................................................................................4233 GROUND DISTRIBUTION.............................................................................4236 HEADLIGHTS......................................................................................4238 HORN............................................................................................4239 INSTRUMENT CLUSTER..............................................................................4240 INTERIOR LIGHTS.................................................................................4241 POWER DISTRIBUTION..............................................................................4243 POWER DOOR LOCKS................................................................................4246 POWER MIRRORS...................................................................................4247 POWER SEATS.....................................................................................4248 POWER TOP/SUNROOF...............................................................................4250 POWER WINDOWS...................................................................................4251 RADIO...........................................................................................4252 SHIFT INTERLOCK.................................................................................4259 STARTING/CHARGING...............................................................................4260 SUPPLEMENTAL RESTRAINTS.........................................................................4262 TRANSMISSION....................................................................................4263 TRUNK, TAILGATE, FUEL DOOR......................................................................4264 WARNING SYSTEMS.................................................................................4265 WIPER/WASHER....................................................................................4265 2003 Ford Mustang Cobra.............................................................................4267 AIR CONDITIONING................................................................................4267 ANTI-LOCK BRAKES................................................................................4270 ANTI-THEFT......................................................................................4271 BODY CONTROL MODULES............................................................................4271 COMPUTER DATA LINES.............................................................................4272 COOLING FAN.....................................................................................4274 CRUISE CONTROL..................................................................................4276 DEFOGGERS.......................................................................................4277 ENGINE PERFORMANCE..............................................................................4278 EXTERIOR LIGHTS.................................................................................4290 GROUND DISTRIBUTION.............................................................................4291 HEADLIGHTS......................................................................................4294 HORN............................................................................................4295 INSTRUMENT CLUSTER..............................................................................4296 INTERIOR LIGHTS.................................................................................4296 POWER DISTRIBUTION..............................................................................4299 POWER DOOR LOCKS................................................................................4301 POWER MIRRORS...................................................................................4302 POWER SEATS.....................................................................................4304 POWER TOP/SUNROOF...............................................................................4306 POWER WINDOWS...................................................................................4307 RADIO...........................................................................................4308 SHIFT INTERLOCK.................................................................................4314 STARTING/CHARGING...............................................................................4316 SUPPLEMENTAL RESTRAINTS.........................................................................4318 TRANSMISSION....................................................................................4319 TRUNK, TAILGATE, FUEL DOOR......................................................................4320 WARNING SYSTEMS.................................................................................4321 WIPER/WASHER....................................................................................4322 2003 Ford Mustang Mac...............................................................................4323 AIR CONDITIONING................................................................................4323 ANTI-LOCK BRAKES................................................................................4326 ANTI-THEFT......................................................................................4327 BODY CONTROL MODULES............................................................................4327 COMPUTER DATA LINES.............................................................................4329 COOLING FAN.....................................................................................4330 CRUISE CONTROL..................................................................................4332 DEFOGGERS.......................................................................................4333 ENGINE PERFORMANCE..............................................................................4334 EXTERIOR LIGHTS.................................................................................4345 GROUND DISTRIBUTION.............................................................................4348 HEADLIGHTS......................................................................................4349 HORN............................................................................................4351 INSTRUMENT CLUSTER..............................................................................4352 INTERIOR LIGHTS.................................................................................4353 POWER DISTRIBUTION..............................................................................4355 POWER DOOR LOCKS................................................................................4357 POWER MIRRORS...................................................................................4359 POWER SEATS.....................................................................................4360 POWER TOP/SUNROOF...............................................................................4362 POWER WINDOWS...................................................................................4363 RADIO...........................................................................................4363 SHIFT INTERLOCK.................................................................................4363 STARTING/CHARGING...............................................................................4363 SUPPLEMENTAL RESTRAINTS.........................................................................4363 TRANSMISSION....................................................................................4363 TRUNK, TAILGATE, FUEL DOOR......................................................................4363 WARNING SYSTEMS.................................................................................4363 WIPER/WASHER....................................................................................4363
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