Ford Mustang (1999-2004) Service Manual: Piston - Pin to Bore Diameter

1. WARNING: Cover the end of the pin bore with a hand or shop rag when removing the retainer ring, since it has a tendency to spring out. Wear eye protection.

NOTE: Piston and piston pins are a matched set and should not be interchanged.

Measure the piston pin bore diameter in two directions on each side. Verify the diameter is within specification.

  • If out of specification, install new components as necessary.

Piston - Pin to Bore Diameter

 

Piston - Pin to Bore Diameter

Piston -Diameter

1. Measure the piston diameter 90 degrees from the piston pin at the point indicated.

  • If out of specification, install new components as necessary.

Piston -Diameter

Piston -to Cylinder Bore Clearance

1. Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore clearance.

    Piston Inspection
    Special Tool(s) Scraper, Piston Ring Groove 303-D033 (D81L-6002-D) or equivalent CAUTION: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can o ...

    Piston - Selection
    NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting a piston. 1. Select a piston size based on the cylinder bore. 2. NOTE: For precision fit, new ...

    Other materials:

    Transmission (Removal)
    1. Disconnect the battery ground cable. For additional information, refer to Section. 2. Lift up on the clutch pedal and secure it in place. 3. Remove the gearshift lever knob (7213). 4. Remove the console panel gearshift plate. Lift the gearshift leve ...

    Cooling Fan Motor and Shroud
    Removal and Installation 1. Disconnect the battery ground cable. 2. Remove the degas bottle or coolant expansion tank. For additional information, refer to Degas Bottle-4.6L(2V) and 4.6L(4V) in this section. 3. Disconnect the cooling fan electrical connecto ...

    Component Tests
    Brake Booster 1. Check the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission (7003) in NEUTRAL, stop the engine (6007) and apply the parking brake control (2780). Apply the brake pedal several times to exhaust all va ...