Seventh Generation Ford Mustang Workshop Manual

Seventh Generation Ford Mustang Workshop Manual

Platform: S650 (Evolution of CD6 Architecture)

1. Engine Systems

Available Powertrains:

1. 2.3L EcoBoost I4
   
   
   • Power: 315–330 HP (Updated twin-scroll turbo)
   • Key Change: Dual-injection system (Port + Direct)
2. 5.0L Coyote V8 Gen 4
   
   
   • Power: 480–500 HP (Revised heads + dual throttle bodies)
   • New Feature: Plasma-sprayed bore liners
3. Hybrid (Confirmed for 2025)
   
   
   • Expected: 450+ HP (V8 + eMotor)
   • Battery: 1.9 kWh Li-ion (Under rear seat)

Torque Specs (Early Data):

• Cylinder Head Bolts: 24 ft-lbs + 90° + 90°
• EcoBoost Timing Chain: 18 ft-lbs (Revised phaser design)

2. Transmission Options

Manual:

• Tremec TR-3160 (GT): 6-speed with rev-matching
• Clutch Upgrade: Dual-mass flywheel (30% increased capacity)

Automatic:

• 10R80 Gen 2 (All Models):
  • Fluid: Mercon ULV (13.2 qt capacity)
  • New Feature: Predictive shift logic using GPS

3. Suspension & Steering

Front Suspension:

• Dual-ball joint MacPherson strut
• GT Performance: Standard MagneRide 4.0 (10ms response)

Rear Suspension:

• Integral Link IRS (Stiffened subframe)
• Handling Pack: Adjustable camber arms (+/- 2°)

Steering:

• EPAS 3.0:
  • Variable ratio (11.6:1 to 16:1)
  • Fault Reset: Requires Ford FDRS software

4. Electrical Architecture

Key Systems:

• SYNC 4A Infotainment: 13.2″ portrait screen
• Digital Cluster: 12.4″ configurable display
• Over-the-Air (OTA) Updates: ECU reprogramming capability

Common Protocols:

• CAN FD (Faster data transmission)
• Ethernet backbone (100Mbps)

5. Brake Systems

GT Performance:

• Front: 400mm rotors / 6-piston Brembo
• Pad Material: Feramic HP2000 (Track-focused)

Hybrid Models:

• Regen Braking: 0.25G energy recovery
• Blended Pedal Feel: Software calibration TSB expected

6. Hybrid System (2025+)

Components:

• eMotor: 45 kW (60 HP) sandwiched in 10R80 bellhousing
• Battery Cooling: Liquid-cooled 400V system

Safety Protocols:

• High-voltage disconnect: Orange handle under rear seat
• First Responder Guide: Isolate via front/rear cut loops

7. Early Technical Service Bulletins

TSB 24-001 (May 2024):

• Issue: Software conflict between drive modes and exhaust valves
• Fix: PCM recalibration (FDRS required)

TSB 24-005 (June 2024):

• Issue: Hybrid powertrain “power limit” errors
• Solution: Replace DC/DC converter (ML3Z-14B227-AA)

8. Special Editions

Dark Horse (2024 Launch Model):

• Engine: 5.0L Coyote (500 HP)
• Trans: TR-3160 with 3D-printed shift gate
• Cooling: Rear axle cooler + auxiliary radiator

9. Diagnostic Tools

Essential Equipment:

• Factory: Ford FDRS + Mongoose Plus V3
• Aftermarket: Autel MaxiSYS Ultra EV

Software Access:

• PTS 2.0: Subscription required for wiring diagrams
• Module Programming: AS-BUILT data via Motorcraft

10. Torque Specs (Partial)

Resources

• Factory Manuals: Access via Ford TechInfo (paid)
• Community Support: Mustang7G Forum
• OEM Tools: Rotunda 303-1745 (Hybrid service kit)

1. Coyote Gen 4 V8 Deep Dive

Dual Throttle Body Operation

• Calibration Procedure:
  1. Start engine, let idle for 2 mins.
  2. Cycle throttle 0-100% 5x using Forscan.
  3. Torque mounting bolts: 8 ft-lbs (M8)

Plasma-Sprayed Cylinder Liners

• Rebuild Considerations:
  • Honing: Use 280-grit diamond stones
  • Piston Clearance: 0.0025-0.0032″ (hypereutectic)

Oil System Updates

• Filter Housing: Aluminum design (FR3Z-6731-B)
• Capacity: 9.2 qt (5W-30 Full Synthetic)

2. Hybrid Powertrain Service

High-Voltage Disable Protocol

1. Remove rear seat cushion.
2. Pull orange disconnect handle (30° upward).
3. Verify 0V at battery terminals with Fluke 1587 FC.

Traction Battery Removal

• Weight: 128 lbs (1.9 kWh pack)
• Lifting Points: M8 threaded inserts (4x)
• Coolant Drain: 1.5 gal Ford Orange concentrate

3. 10R80 Gen 2 Transmission

Adaptive Shift Reset

1. Drive at 45-60 mph for 10 mins.
2. Perform 5 full-throttle upshifts.
3. Use Forscan to confirm “Adaptations Complete.”

Predictive Shift Logic

• GPS Integration:
  • Learns 100 frequent routes
  • Pre-positions gears for hills/curves
• Override: Hold +/- paddles for 5s

4. MagneRide 4.0 Service

Damper Calibration

1. Install chassis ears (front/rear).
2. Run Ford IDS “Ride Quality Verification.”
3. Adjust fluid viscosity via software (5 settings).

Strut Replacement

• Special Tool: Rotunda 307-210 (magnetic alignment jig)
• Bleed Procedure: 30° tilt + vertical cycle x10

5. Digital Cluster Programming

Track Display Mode

• Activation:
  • Enter developer mode (swipe down + tap build number x7).
  • Enable “TrackUI” flag.
• Metrics:
  • Driveshaft torque (live readout)
  • Individual wheel power distribution

Screen Delamination TSB

• Symptom: Ghost touches/halo effect
• Fix: Replace display (Ford ML3Z-10849-C)

6. Dark Horse Model Specifics

3D-Printed Shift Gate

• Material: Ti-6Al-4V titanium
• Replacement: Requires ECU reprogramming

Auxiliary Radiator Service

• Location: Driver-side wheel well
• Flush Procedure: 50/50 mix Ford Yellow + distilled water

7. Early Production Issues

Fault Code U3000:97

• Cause: CAN FD bus conflicts with aftermarket mods
• Fix: Install Ford-approved gateway module (PR3Z-14G229-A)

Brake Pedal Vibration (Hybrid)

• TSB 24-012: Reprogram ABS module
• Threshold: >0.15G regen force

8. Performance Upgrades

Stage 1 Package (Ford Performance)

• Includes:
  • Cold air intake (M-9603-M52)
  • ProCal 4+ tuner (+58 HP on 93 octane)
  • 2-year powertrain warranty

Carbon Fiber Driveshaft

• P/N: Ford M-4602-M52
• Balancing: Requires 0.01 oz-in tolerance

9. Wiring Diagrams (Partial)

SYNC 4A Power Circuit

• Fuse: F1.32 (25A in BJB)
• CAN Bus: HS3-C (500kbps)

Hybrid Battery Cooling

• Pump: 400V brushless (ML3Z-9B407-A)
• Flow Rate: 1.2 gal/min @ 45 psi

10. Special Tools List

1. Battery Service Kit: Rotunda 307-215 (insulated gloves + 1000V multimeter)
2. Damper Tester: Rotunda 307-218 (MagneRide 4.0)
3. Prop Shaft Alignment: Rotunda 307-221 (laser-guided)

1. Hybrid Battery Management

State of Health (SOH) Check

1. Forscan Method:
   • Navigate: PCM > Powertrain > Hybrid Battery
   • Acceptable Degradation: <8% @ 50k miles

Cell Balancing Procedure

• Tool: Rotunda 307-225 (BMS Pro)
• Cycle Time: 6-8 hours (0.5A trickle charge)

2. Advanced Driver-Assist Systems

BlueCruise 1.3 Calibration

1. Camera Alignment:
   • Use Rotunda 307-230 (calibration target)
   • Road Test: 40 mph on arrow-straight road

LiDAR Calibration (Dark Horse Track Pack)

• Location: Front grille emblem
• Test Pattern: 307-235 laser grid required

3. Carbon Fiber Component Repair

Wheel Refinishing

• Sanding: 800 → 1200 → 2000 grit (dry)
• Clear Coat: PPG D8125 (UV-stable)

Splitter Clearance Adjustment

• Track Mode: 1.5″ ground clearance (auto-retract)
• Manual Override: Forscan parameter 726-42-01

4. Over-the-Air (OTA) Update Protocol

Failed Update Recovery

1. Force reboot: VOL↓ + SEEK→ (hold 10s)
2. Download via USB: Ford OTA Recovery Tool
3. Re-initiate via SYNC menu

Module Prioritization

1. PCM > ABS > BCM > Infotainment
2. Minimum 65% battery charge required

5. Performance Cooling Systems

Diff Cooler Retrofit

• Kit: Ford M-4033-M52 (plumb to aux radiator)
• Pump Flow Test: 0.8-1.2 GPM @ 45 psi

Intercooler Sprayer (Dark Horse)

• Capacity: 1.5 gal (50/50 meth-water mix)
• Nozzle Pattern: 15° fan @ 45 psi

6. Corrosion Prevention

Underbody Coatings

• Factory: 3M 08876 epoxy (2.3 mil thickness)
• Touch-Up: 3M 08877 (conductive primer required)

Aluminum Panel Repair

• Riveting: CherryMax CR3252 (0.187″ grip)
• Sealant: 3M 08307 (conductive)

7. Track Telemetry Integration

Data Export Protocol

1. Insert USB-C into dash port
2. Select “Session Export” in Track Apps
3. Formats: CSV (basic) / MOTEC (advanced)

Driveshaft Torque Monitoring

• Live Readout: ±1,200 lb-ft resolution
• Overload Alert: >850 lb-ft triggers warning

8. HVCH (Hybrid Voltage Converter)

Diagnostic Codes

• P0D31: Insulated gate bipolar transistor (IGBT) failure
• Fix: Replace module (ML3Z-14G670-A)

Coolant Flow Test

• Spec: 130°F ±5° at outlet (max load)
• Tool: Rotunda 307-240 (thermal clamp meter)

9. 3D-Printed Parts Service

Shift Gate Replacement

1. Scan original with Einscan HX (0.01mm res)
2. Print: HP MJF 5210 PA-12 material
3. Post-process: Vapor polish 15 mins

Warranty Note: Non-Ford printed voids powertrain coverage

10. Emerging TSBs (Q4 2024)

TSB 24-022:

• Issue: MagneRide 4.0 “float” mode imbalance
• Fix: Damper firmware V2.1.7

TSB 24-025:

• Issue: Hybrid AC compressor harmonics
• Solution: Isolate with ML3Z-19C836-B dampers

11. Master Torque Spec Addendum

12. Factory Training Resources

• Web: Ford STARS > S650 Certifications
• Courses:
  • Hybrid High-Voltage Service (3 days)
  • MagneRide 4.0 Master Tech (2 days)
  • SYNC 4A Programming (1 day)