Fourth Generation Ford Mustang Workshop Manual

(1994–2004 SN-95/New Edge)

1. Engine Systems

4.6L Modular V8 (2V/4V)

Specifications:

• Displacement: 4.6L (281ci)
• Bore/Stroke: 3.55″ x 3.54″
• Compression Ratio:
  • 2V: 9.4:1
  • 4V (Cobra): 9.85:1

Valve Adjustment (4V):

• Hydraulic lash adjusters (zero clearance)
• Torque: Rocker arm bolts – 18 ft-lbs

Timing Chain Replacement:

1. Lock crankshaft with Ford tool 303-507.
2. Align timing marks:
   • Crank keyway at 12 o’clock.
   • Camshaft dots facing each other.
3. Torque:
   • Cam sprocket bolts: 18 ft-lbs
   • Timing cover bolts: 89 in-lbs

2. Transmission & Drivetrain

T-45/T-56 Manual Transmission

Gear Ratios:

Fluid Specifications:

• T-45: Mercon V (3.5 qts)
• T-56: Dexron III (4.0 qts)

4R70W Automatic Transmission

Shift Kit Installation:

1. Replace separator plate (Ford 4L2Z-7Z490-AA).
2. Torque: Valve body bolts – 97 in-lbs

3. Suspension & Steering

Front Suspension:

• Spring Rate:
  • GT: 450 lb/in
  • Cobra: 600 lb/in
• Alignment Specs:
  • Camber: -0.5° to -1.0°
  • Toe: 0.05″ IN

IRS (1999–2004 Cobra):

• Bushing Replacement:
  1. Press out rubber bushings (OTC 1123 tool).
  2. Install polyurethane bushings (Energy Suspension 4.3154).

4. Electrical System

Common Repairs:

• PATS Key Programming:
  
  
  1. Insert master key, turn to RUN for 3 sec.
  2. Cycle ignition OFF→ON 8x within 10 sec.
• Blend Door Actuator Replacement:
  
  
  1. Remove glove box (7mm screws).
  2. Torque: Actuator screws – 18 in-lbs

Wiring Diagrams:

• Fuel Pump Circuit:
  • Relay (Pin 30 → 87): 12V feed (14ga red wire)
  • Inertia switch: Under passenger kick panel

5. Brake Systems

Cobra Brembo Upgrade:

1. Spindle Mod: Grind 0.125″ for caliper clearance.
2. Master Cylinder: Ford 2W7Z-2140-AA (1-1/16″).

ABS Diagnostics:

• Tool: Ford NGS/Mongoose Pro
• Test Mode: Cycle pump 5x (30-sec intervals).

6. Performance Upgrades

Supercharger Kit (Vortech V-2):

• Boost: 6–8 PSI (stock internals safe)
• Fuel Upgrades:
  • 42 lb/hr injectors
  • Walbro 255 LPH pump

Exhaust Header Install:

• Long-Tubes: Requires EGR delete (tuner required).
• Torque: Header bolts – 25 ft-lbs (staged)

7. Torque Specifications

8. Fluid Capacities

9. Troubleshooting

Engine Misfire (4.6L):

1. Test COP coils (4.6–5.2Ω resistance).
2. Inspect spark plugs (gap: 0.052–0.056″).

Harsh Shifts (4R70W):

1. Replace separator plate (Ford 4L2Z-7Z490-AA).
2. Reset adaptive learning (cycle ignition 10x).

10. Special Tools

11. Maintenance Schedule

12. Appendix

Parts Cross-Reference:

Wiring Color Codes:

• Red/Blue: Ignition +12V
• Black/White: Ground

13. Advanced Diagnostics

P0171/P0174 (Lean Codes):

1. Smoke Test: Check for vacuum leaks (smoke machine required).
2. MAF Cleaning: Use CRC 05110 (no direct contact).
3. Fuel Pressure Test: 35–45 PSI at idle.

ABS Light On:

1. Wheel Speed Sensor Test:
   • Resistance: 800–1,400Ω (front), 1,000–1,600Ω (rear).
   • Air gap: 0.028–0.032″.

14. Body & Interior

Convertible Top Repair:

1. Hydraulic Pump Reset:
   • Cycle ignition 5x with top switch held down.
2. Seal Replacement:
   • Use 3M 08609 urethane.

Dashboard Removal:

1. Steering Column: Lower with Torx T50 (18 ft-lbs reinstall).
2. Torque: Dashboard bolts – 89 in-lbs.

15. Factory Recalls/TSBs

TSB 03-06-01:

• Issue: Harsh 1-2 shift (4R70W).
• Fix: Reprogram PCM with Ford IDS.

Recall 99S27:

• Issue: Speed control deactivation switch fire risk.
• Fix: Replace switch (Ford F65Z-9C968-AA).

16. Performance Tuning

EEC-V PCM Tuning:

• Software: SCT X4 or HPTuners.
• Parameters:
  • Rev limit: 6,250 RPM (stock) → 7,000 RPM (safe).
  • Fuel injector slope: 42 lb/hr (matched to upgrades).

Suspension Upgrades:

• Coilovers: KW Variant 3 (600 lb/in front spring rate).
• Sway Bars: Eibach 3582-320 (35mm front/24mm rear).

17. Torque Spec Addendum

18. Fluid Spec Addendum

19. Special Procedures

Headlight Motor Gear Replacement:

1. Gear Kit: Ford F5RZ-13A025-AA.
2. Test Cycle: Run motors 10x after repair.

Fuel Tank Replacement:

1. Support: Use transmission jack.
2. Vent Line Routing: Avoid kinks near EVAP canister.

20. Final Checks

Post-Repair Verification:

1. Idle Relearn:
   • Warm engine to 190°F.
   • Idle 10 mins with A/C off.
2. Road Test: Monitor for driveline vibration (55–65 MPH).