Ford Mustang (1999-2004) Service Manual: Torque Converter (Disassembly and Assembly of Subassemblies)

1. A new or remanufactured torque converter must be installed if one or more of the following statements is true:

  • A torque converter malfunction has been determined based on complete diagnostic procedures.
  • Converter stud or studs, impeller hub or bushing are damaged.
  • Discoloration (due to overheating).
  • The torque converter is found to be out of specification when carrying out one of the following torque converter checks:
  • One-Way Clutch Check
  • End Play Check
  • Stator to Turbine Interference Check
  • Stator to Impeller Interference Check
  • Torque Converter Leak Check
  • Evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes:
  • Major metallic failure.
  • Multiple clutches or clutch plate failures.
  • Sufficient component wear which results in metallic contamination.
    Assembly
    1. NOTE: Lubricate direct clutch piston inner seal and seal protector with petroleum jelly. Using the special tool, install the inner piston seal. Install the seal with sealing lip facing down. ...

    Torque Converter Cleaning And Inspection
    Material Item Specification MERCON V Automatic Transmission Fluid XT-5-QM, XT-5-DM MERCON V 1. If a new torque converter is being installed, continue with Substep 2 of Step 2. ...

    Other materials:

    Exhaust Gas Recirculation (EGR) Valve
    Removal and Installation NOTE: The 4.6L, 2V is shown. The 3.8L is similar. 1. Disconnect the vacuum hose. 2. Disconnect the EGR tube from the EGR valve. 3. Remove the two bolts, the EGR valve and the gasket. 4. NOTE: Install a new gasket. To install, ...

    Cleaning the windows and wiper blades
    The windows and wiper blades should be cleaned regularly. If the wipers do not wipe properly, substances on the vehicle’s glass or the wiper blades may be the cause. These may include hot wax treatments used by commercial car washes, water repellent coatings ...

    Component Tests
    Steering Linkage 1. NOTE: Excessive vertical motion of the studs relative to the sockets may indicate excessive wear. With the parking brake applied, perform the following: Have an assistant rotate the steering wheel back and forth 360 degrees and watch ...