[blazinsteed]

ENGINE MISFIRE OR ROUGH RUNNING—COIL ON TSB 04-16-1
PLUG (COP) IGNITION SYSTEMS—WDS COP KIT
DIAGNOSTIC TIPS
FORD: LINCOLN:
1996-1999 Taurus SHO 1997-1998 Mark VIII
1998-2005 Crown Victoria, Mustang 1998-2002 Continental
2000 Taurus 1998-2005 Town Car
2002-2005 Thunderbird 2000-2005 LS
2003-2005 Focus 1998-2005 Navigator
2004-2005 Taurus 2002-2003 Blackwood
1997-2005 E-Series, Expedition, F-150 2003-2005 Aviator
1999-2005 F-Super Duty MERCURY:
2000-2005 Excursion, F-53
1998-2005 Grand Marquis
2001-2005 Escape
2000 Sable
2002-2005 Explorer
2004-2005 Sable
2002-2005 Mountaineer
This article supersedes TSB 03-14-04 to update the The following material will detail the diagnostic
vehicle applications and model years. steps on WDS to take the guesswork out of misfire
diagnosis using the COP Kit. The following
ISSUE procedure is for cylinder specific misfires and not
Approximately 50% of coil on plug (COP) coils random misfires. Random misfires have a different
returned for warranty do not have a problem. root cause and are not covered by this TSB.
Misfire Definition: A misfiring cylinder is lacking ACTION
power relative to the other cylinders. The causes for The misfiring cylinder must be identified through
a cylinder specific misfire could be fuel, spark, or Self-Test misfire codes or through WDS Power
mechanical problems. Balance. Rule out base engine problems, rule out
fuel problems, and then look at ignition problems
Perform a thorough visual inspection. If no visible
(be sure to rule out coil primary circuit issues).
concerns are found use the following WDS tools for
Once the above steps have been completed, and
misfire diagnosis:
the issue is in the secondary part of the ignition
• Self-test (Check for codes first) system, the oscilloscope procedure outlined in this
TSB can isolate the difference between a coil or • Power Balance (Identify the cylinder of concern)
spark plug problem. • Relative Compression (Rule out a possible
mechanical issue) SERVICE PROCEDURE
• Fuel (Make sure fuel injectors are not restricted)
The optional WDS COP Kit available through • Ignition (Make sure spark plugs and coils are
Rotunda will provide more accurate diagnosis and working properly)
help reduce replacement of non-defective parts. The
• Oscilloscope (Detailed signal analysis) Kit (418-FS528) can be purchased through
1-800-ROTUNDA.
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do
the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper
vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a
Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation
determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.The information in this Technical Service Bulletin
(TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates.The most recent information is
available through Ford Motor Company’s on-line technical resources.
Copyright ã 2004 Ford Motor Company PAGE 1
TSB 04-16-1 (Continued)
NOTE NOTE
USE THE ENCYCLOPEDIA BUTTON IN THE LIVE DISPLAY HAS TO AVERAGE IGNITION
LOWER LEFT CORNER OF THE SCREEN FOR VALUES BECAUSE THERE IS TOO MUCH DATA
DETAILED INFORMATION ON THE WDS TOOL TO DISPLAY. MAKE A CAPTURE TO VIEW EACH
BEING DISPLAYED. ENGINE EVENT WITHOUT AVERAGING. THIS
CAN BE HELPFUL WHEN THE PROBLEM IS
If there is a self-test code identifying a particular INTERMITTENT. IF THE MISS IS EXTREMELY
cylinder then you just need to determine if it is a INTERMITTENT AND DOES NOT SHOW UP IN
fuel, ignition, or possibly a mechanical problem. IGNITION, PROCEED TO STEP 4.
Proceed to Step 2 after running Relative
Compression to rule out any mechanical issues. If If either spark duration or peak KV on the Red
there is no self-test code and the customer concern Probe (Suspect Cylinder) are offset from the values
is a miss, proceed to Step 1. displayed on the Black Probe (Known Good
Cylinder) then the problem is in the ignition system.
Step 1: (Select Toolbox Icon, then Powertrain, Rule out coil primary circuit issues before
then Power Balance) proceeding to coil secondary issues such as the
spark plug, coil boot, or possibly the coil. Use the The cylinder specific miss has to be identified as
WDS Oscilloscope with the COP kit to determine if shown in the example in Figure 2 in order to
the issue is the coil or the spark plug. proceed with the remaining steps. If the miss does
not occur at idle (in the bay), try to brake torque Step 4: (Select Toolbox, then Oscilloscope)
the engine. This extra loading should reproduce the
miss in the bay. If the miss cannot be reproduced WARNING
during brake torque, select Relative Compression SECONDARY IGNITION VOLTAGES ARE VERY
under Powertrain on WDS before going on a road HIGH. KEEP HANDS AND TOOLS AWAY FROM
test to rule out mechanical problems. If Relative THE END OF THE COIL THAT SUPPLIES THE
Compression shows a problem then the base SPARK.
engine issue must be serviced. If Relative
SET-UP: With the engine off, pull the suspect coil Compression results are good (Figure 3), road test
from the cylinder well and turn it upside down so under as many different driving conditions as
the coil cannot spark to any other surface as shown possible until the miss occurs on Power Balance.
in Figure 1. Wrap a clean shop cloth around the Some misses may be very intermittent so be patient
hard shell of the coil to help keep the coil propped and concentrate on steady load conditions. Once a
up and stable. cylinder dropout is identified proceed to Step 2.
Step 2: (Select Toolbox Icon, then Powertrain,
then Fuel System Test)
Run Fuel System Test on WDS to determine if
there may be a fuel problem. After completing fuel
Pressure/Leakdown test, select Injector flow to
isolate a restricted injector as shown in Figure 4. If
all the injectors are within specification, proceed to
Step 3.
Step 3: (Select Toolbox Icon, then Powertrain,
then Ignition System Test)
Run Ignition System Test on WDS to determine if
there is an ignition problem. Look at both duration
Figure 1 - Article 04-16-1 (DUR) and kilovolts (KV) and look for values that
standout from the rest as shown in Figure 5 and CAUTION
Figure 6. THE COIL BOOT CAN BE DAMAGED IF THE
COIL SPARKS TO ANOTHER SURFACE DURING
THIS PROCEDURE.
PAGE 2
TSB 04-16-1 (Continued)
Keep the coil connected to the harness and leave Figure 8 and Figure 9 are examples of problem
the WDS COP clip attached to the coil. Route the coils. Replace the coil if the waveform is similar to
coil clip wire and cable away from the coil being Figures 8 or 9. The coil is causing the misfire when
tested as well as other coils to avoid noise the peak firing appears like those shown in Figures
interference. Disconnect the injector of the cylinder 8 and 9. Notice the difference in the peak-firing
being tested so raw fuel is not washing the cylinder. signal when compared to the good peak signal in
This is a stress test for the coil. The type of Figure 7.
waveform displayed on the oscilloscope will show
Figure 9 shows a more dramatic fault in the peak whether a coil or the plug is the problem if all
failure. previous steps have been followed. Keep hands
and tools away from the end of the coil that Most root causes of misfire issues can be identified
supplies the spark. quickly using the steps outlined above. Some
misfire issues can be difficult making the COP Stress Test Procedure:
oscilloscope an important part of your diagnostic
Go to the Oscilloscope Tool and select Channel 3, toolbox.
then select Auto, then select
WARRANTY STATUS: Eligible Under Provisions Of COP_STRESS_TEST_RED. This pre-configured
New Vehicle Limited setting will zoom-in on the peak firing of the coil
Warranty Coverage being tested. Start the engine and be sure the coil
is not sparking to any surface. If the coil is sparking
to other surfaces, turn the engine off immediately
and readjust the coil so it cannot spark to any other
surface. Restart the engine and touch the Red Man
icon to start the oscilloscope. All settings are
pre-configured and no adjustments are necessary.
Compare the waveform you get with the examples
provided in Figures 7, 8, and 9). Figure 7 is a good
waveform. If your waveform is similar to Figure 7
the coil is working correctly. Suspect the spark plug.

Cant post the pic sorry.

Re: TSB UPDATE as June 25, 2005 for 03 MACH1

--------------------------------------------------------------------------------

Quote:
Originally Posted by crash
I'm interested in the following, please:

04-5-3
CLIMATE CONTROL - RATTLE NOISE FROM INSTRUMENT PANEL VENTS - DIFFICULT TO ADJUST
NOISE - CLIMATE CONTROL - RATTLE NOISE FROM INSTRUMENT PANEL VENTS - DIFFICULT TO ADJUST

04-1-2
BODY - INTERIOR TRIM - HEADLINER SAGGING IN REAR




• CLIMATE CONTROL—RATTLE NOISE FROM Article No.
INSTRUMENT PANEL VENTS—DIFFICULT TO 04-5-3
ADJUST
• NOISE—CLIMATE CONTROL—RATTLE NOISE
FROM INSTRUMENT PANEL VENTS—DIFFICULT TO
ADJUST
FORD: 2001-2004 MUSTANG
OPERATION DESCRIPTION TIME ISSUE
040503A Replace Barrel Vent 0.3 Hr. Some 2001-2004 Mustang vehicles may exhibit
(Includes Time To Replace climate control panel vents (barrel vent) with vanes
One Or All Vents) that are difficult to adjust, and/or may make a
DEALER CODING rattling type noise. This may be due to detachment
CONDITION of the air vanes from the pilot holes in the vent
BASIC PART NO. CODE housing.
19893 42
ACTION
To service, install revised vent (3R3Z-19893-AB).
The barrel vents are now sold and serviced
separately. Refer to the Service Procedure below.
SERVICE PROCEDURE
1. Order replacement vent (3R3Z-19893-AB), one
(1) for each vent requiring replacement.
2. Remove the vent by prying it away with a flat
screwdriver (Figure 1).
3. Install the revised vent by pressing the new
vent into place (Figure 2).
4. Repeat Steps 1-3 as needed.
PART NUMBER PART NAME
3R3Z-19893-AB Vent Louvre Assembly
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under Provisions Of
New Vehicle Limited
Figure 1 - Article 04-5-3 Warranty Coverage
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do
the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper
vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a
Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation
determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.The information in this Technical Service Bulletin
(TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates.The most recent information is
available through Ford Motor Company’s on-line technical resources.
Copyright ã 2004 Ford Motor Company PAGE 1
Article No. 04-5-3 Cont’d.
Figure 2 - Article 04-5-3
PAGE 2



BODY—INTERIOR TRIM—HEADLINER SAGGING IN Article No.
REAR 04-1-2
FORD: 2001-2003 MUSTANG
10. Move the template away from the pen mark ISSUE
and put a 5mm (0.20²) hole in the headliner Some 2001-2003 Mustang Coupes may exhibit the
using an awl. headliner sagging in the rear of the vehicle.
CAUTION ACTION
BE CAREFUL NOT TO PUSH THE AWL INTO To service, install a push pin fastener to secure the
THE ROOF SHEET METAL. IT WILL CAUSE A headliner in its proper position. Refer to the
DENT ON THE ROOF EXTERIOR. following Service Procedure.
11. Install the appropriately colored push pin SERVICE PROCEDURE
(included in the kit), by pushing it through the
newly made hole in the headliner and into the 1. Obtain Service Kit 1R3Z-63519E80-AA. The Kit
existing rear sheet metal header hole. will contain a template and push-pins.
12. Remove the dome lamp screws and remove 2. Remove fuse #37 from the instrument panel
the template. fuse box for the dome lamp.
13. Reassemble the dome lamp per Section 417-02 3. Remove the dome lamp lens (refer to
of the Workshop Manual. Workshop Manual Section 417-02).
14. Reinstall fuse #37 into the instrument panel 4. Remove the three (3) dome lamp screws as
fuse box. shown in Section 417-02 of the Workshop
Manual.
PART NUMBER PART NAME
5. Place the template from the Kit over the front 1R3Z-63519E80-AA Kit (Headliner Repair)
two (2) holes in the dome lamp, with the other
end of the template pointing towards the
OTHER APPLICABLE ARTICLES: NONE backglass.
WARRANTY STATUS: Eligible Under Provisions Of
New Vehicle Limited 6. Install the two (2) screws into the holes and
Warranty Coverage hand tighten.
OPERATION DESCRIPTION TIME
7. Pull the template straight back towards the rear 040102A Install A Push Pin 0.3 Hr.
of the car following the headliner contour. Fastener To Secure The
Headliner 8. Locate the rearward hole that is marked on the
DEALER CODING template.
CONDITION
BASIC PART NO. CODE 9. While pushing the headliner towards the roof of
63519C08 07 the vehicle, use a pen to push through the
marked hole on the template and mark the
headliner.
NOTE
MAKE SURE THAT THE TEMPLATE IS
STRAIGHT WITHOUT ANY SIDE TO SIDE
VARIATION.
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do
the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper
vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a
Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation
determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.The information in this Technical Service Bulletin
(TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates.The most recent information is
available through Ford Motor Company’s on-line technical resources.
Copyright ã 2004 Ford Motor Company PAGE 1

MANUAL TRANSMISSION HARD TO SHIFT INTO TSB 04-19-8
FIRST/REVERSE FROM A STOP
FORD:
1999-2004 Mustang
3. Visually examine the pedal down-stop to see if ISSUE
it is preventing the pedal from reaching its full Some 1999-2004 Mustang vehicles equipped with a
travel to the carpet. Correct if necessary by T5, T45 or TR3650 manual transmission, may
removing the rubber pad on the down-stop. If exhibit a hard to shift condition into first or reverse
the condition is corrected return the vehicle to gears from a stop. This may be due to an
the customer. If the condition is not corrected incomplete disengagement of the clutch (lack of
proceed to Step 4. clutch pedal reserve).
4. Additional travel can be obtained by loosening ACTION
the clutch pedal shaft nut and adjusting as
Refer to the following Service Procedure. It may be
needed per Section 308-00 of the Workshop
necessary to adjust the clutch pedal down-stop and
Manual. If the condition is corrected return the
the clutch pedal shaft nut to gain full pedal travel.
vehicle to the customer. If the condition is not
corrected proceed to Step 5. SERVICE PROCEDURE
5. If inadequate reserve is still present refer to 1. Lift up on the clutch pedal to reset it.
Workshop Manual Section 308-00 for clutch
2. Measure the clutch reserve per the instructions pressure plate and disc diagnostics.
listed in the Workshop Manual Section 308-00,
WARRANTY STATUS: Eligible Under Provisions Of Diagnosis and Testing, Manual Transmission
New Vehicle Limited and Clutch.
Warranty Coverage
NOTE DEALER CODING
THE MINIMUM RESERVE NEEDED FOR GT, LX CONDITION
AND 1999-2001 COBRA IS 19 MM (3/4²). BASIC PART NO. CODE
7519 07
a. If the measurement obtained is larger than
these values, DO NOT CONTINUE WITH
THIS TSB. Follow normal Workshop Manual
diagnostics listed in Section 308-03.
b. If the measurement obtained is less than
these values, make sure that the floor mat
or excessive material under the carpet is not
preventing the pedal from reaching its full
travel. Correct any obstruction, if the
condition is corrected return the vehicle to
the customer. If the condition is not
corrected proceed to Step 3.
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do
the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper
vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a
Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation
determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.The information in this Technical Service Bulletin
(TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates.The most recent information is
available through Ford Motor Company’s on-line technical resources.
Copyright ã 2004 Ford Motor Company PAGE 1


Re: TSB UPDATE as June 25, 2005 for 03 MACH1

--------------------------------------------------------------------------------

Quote:
Originally Posted by Yellow Jacket
Please post:

04-15-6
TR3650 MANUAL TRANSMISSION - JUMPS OUT OF GEAR 2ND AND/OR 3RD - CLASH NOISE AND/OR RASPY FEEL ON GEAR ENGAGEMENT



TR3650 MANUAL TRANSMISSION—JUMPS OUT OF TSB 04-15-6
GEAR 2ND AND/OR 3RD—CLASH NOISE AND/OR
RASPY FEEL ON GEAR ENGAGEMENT
FORD:
2001-2003 Mustang
4. Clean oil from area 26 mm (1²) below the ISSUE
transmission fill plug (Figure 1) and install the Some 2001-2003 Mustang vehicles, equipped with
oil fill sticker included in the kit. TR3650 5 speed manual transmission may exhibit a
clash noise and/or a raspy (rough) feel on gear
engagement during 1-2 or 2-3 shifts. The
transmission may also exhibit a jump-out from 2nd
and/or 3rd gear. The condition may be more
pronounced when the transmission is colder than
40° F (5° C).
ACTION
To service, install a Synchro Kit. The kit includes
2nd main shaft gear, 1-2 synchronizer assembly,
3rd main shaft gear, 3-4 synchronizer assembly, the
1-2 and 3-4 shift fork and rail assemblies, blocking
rings and an oil fill level sticker. Add new
transmission fluid and fill to the revised lower level.
Refer to the following Service Procedure. Figure 1 - Article 04-15-6
SERVICE PROCEDURE NOTE
THIS TSB DOES NOT AUTHORIZE NOTE
REPLACEMENT OF THE CLUTCH ASSEMBLY ALL COMPONENTS IN THE KIT ARE REVISED
AND RELEASE BEARING FOR NORMAL WEAR. AND MUST BE REPLACED.
IF SUFFICIENTLY WORN, THE CUSTOMER MAY
NOTE WISH TO HAVE THEM REPLACED AT THEIR
EXPENSE. SOME DISCOLORATION AND LIGHT BLOCKING RINGS MAY APPEAR DIFFERENT
SCRATCHES ON THE FLYWHEEL OR THAN THOSE BEING REMOVED FROM THE
PRESSURE PLATE ARE CONSIDERED NORMAL TRANSMISSION.
AND RESURFACING IS NOT REQUIRED.
NOTE
5. Reinstall the transmission. REFER TO THE WORKSHOP MANUAL SECTION
308-03 TO AID IN THE FOLLOWING
6. Fill the transmission with 3.0 liters (6.3 pints) of
PROCEDURE.
Motorcraft Mercon ATF (XT-2-QDX). The full fill
level is approximately 19 mm (0.75²) below the 1. Remove the transmission from the vehicle.
fill hole.
2. Disassemble the transmission.
NOTE
3. Install all of the revised components included in SHIFT QUALITY MAY IMPROVE FURTHER WITH
kit 3R3Z-7124-AC. BREAK IN, APPROXIMATELY 644 KILOMETERS
(400 MILES) OF DRIVING.
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do
the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper
vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a
Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation
determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.The information in this Technical Service Bulletin
(TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates.The most recent information is
available through Ford Motor Company’s on-line technical resources.

TSB 04-15-6 (Continued)
PART NUMBER PART NAME
3R3Z-7124-AC Synchro Kit
XT-2-QDX Mercon ATF
WARRANTY STATUS: Eligible Under Provisions Of
New Vehicle Limited
Warranty Coverage
OPERATION DESCRIPTION TIME
041506A Install Components 5.6 Hrs.
Included In Kit (Includes
Time To Remove And
Install Transmission And
Final Road Test)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7124 42