[03whitemach]

TSB
04-24-8 STEERING RACK NOISE

Publication Date: November 22, 2004

FORD: 2002-2004 Mustang


ISSUE:
Some 2002-2004 Mustang vehicles may exhibit a squeak or creak type noise while turning.

ACTION:
Replace the power steering gear tube bracket. Use only replacement parts that have a green paint dot. Torque the fasteners to 52 lb-ft (70 N-m).


PART NUMBER PART NAME
E5DZ-3K620-A Bracket


WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage


TSB
04-24-21 SAFETY BELT RETRACTION SPEED

Publication Date: November 30, 2004

FORD: 2000-2004 Mustang
2000-2005 Crown Victoria, Taurus
2000-2003 Explorer Sport, Windstar
2000-2004 Ranger
2000-2005 E-Series, Excursion, Expedition, Explorer, F-150, F-Super Duty
2001-2005 Escape, Explorer Sport Trac
2004-2005 Freestar
2005 Escape Hybrid
2004-2005 F-650, F-750
LINCOLN: 2000-2002 Continental
2000-2005 LS, Town Car, Navigator
2003-2005 Aviator
MERCURY: 2000-2005 Grand Marquis, Sable, Mountaineer
2004-2005 Monterey
2005 Mariner


ISSUE:
A service kit is now available to improve safety belt retraction speed.

ACTION:
See the part application chart and select the appropriate kit. Follow the Instruction Sheet included in the kit. Refer to Workshop Manual Section 501-20a for additional information.

NOTE: IF TEFLON TAPE IS ALREADY PRESENT ON THE SAFETY BELT GUIDE RING (D-RING), DO NOT CONTINUE WITH THIS TSB.



NOTE: EACH KIT SERVICES TWO (2) BELTS.



NOTE: DOES NOT APPLY TO AVIATOR/EXPLORER 4DR/MOUNTAINEER FRONT SAFETY BELTS FOR VEHICLES BUILT AFTER 6/25/2004, OR REAR SAFETY BELTS FOR VEHICLES BUILT AFTER 10/22/2004, BECAUSE TEFLON TAPE IS INSTALLED DURING PRODUCTION.



PART APPLICATION CHART
Part Number Application
YR3Z-63611D70-AA MUSTANG

XW4Z-63611D70-AA LINCOLN LS
XW4Z-63611D70-AA E-SERIES

3L2Z-78611D70-AB CONTINENTAL
3L2Z-78611D70-AB CROWN VICTORIA
3L2Z-78611D70-AB EXPEDITION
3L2Z-78611D70-AB EXPLORER SPORT
3L2Z-78611D70-AB EXPLORER SPORT TRAC
3L2Z-78611D70-AB EXCURSION
3L2Z-78611D70-AB ESCAPE
3L2Z-78611D70-AB ESCAPE HYBRID
3L2Z-78611D70-AB FREESTAR
3L2Z-78611D70-AB F-SERIES SUPER DUTY
3L2Z-78611D70-AB F-150
3L2Z-78611D70-AB F650/F750
3L2Z-78611D70-AB GRAND MARQUIS
3L2Z-78611D70-AB MARINER
3L2Z-78611D70-AB MONTEREY
3L2Z-78611D70-AB NAVIGATOR
3L2Z-78611D70-AB RANGER
3L2Z-78611D70-AB SABLE
3L2Z-78611D70-AB TAURUS
3L2Z-78611D70-AB TOWN CAR
3L2Z-78611D70-AB WINDSTAR

3L2Z-78611D70-AB AVIATOR, EXPLORER 4DR/MOUNTAINEER (BUILT BEFORE 6/25/2004 FOR FRONT SEAT, OR BUILT BEFORE 10/22/2004 FOR REAR SEAT)


NOTE: THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS NEEDED TO COVER THE REQUIRED REPAIRS.




WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage



TSB
04-24-20 LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNING MANEUVERS

Publication Date: November 30, 2004

FORD: 2002-2005 Crown Victoria, Mustang, Explorer
2003-2005 Expedition
2004-2005 F-150
LINCOLN: 2002-2005 Town Car
2003-2005 Navigator
MERCURY: 2002-2005 Grand Marquis, Mountaineer


This article supersedes TSB 04-17-5 to update the model year and vehicle line coverage.

ISSUE:
Some 2003-2005 Expedition/Navigator, 2004-2005 F-150 vehicles equipped with a 9.75" or 8.8" limited slip rear axle, and 2002-2005 Explorer 4dr, Mountaineer, Crown Victoria, Grand Marquis, Town Car, and Mustang vehicles equipped with 8.8" limited slip rear axle, may exhibit a chatter, shudder, a binding sensation, or a vibration during low speed turns. On 4x4 vehicles, the sensation may appear to be originating from the front axle or the steering gear.

ACTION:
First verify the condition. On 4x4 trucks ensure that the vehicle is in 2WD, to isolate the rear axle. On all vehicles, turn the wheel fully right (or fully left) and then accelerate the vehicle. If the condition is verified to be in the rear axle, replace the limited slip clutch pack.

SERVICE PROCEDURE

CAUTION: INSTRUCT THE CUSTOMER NOT TO TOW WITH THE VEHICLE FOR 500 MILES AFTER THIS REPAIR, TO ALLOW THE AXLE TO BREAK-IN PROPERLY.



Order and install the appropriate clutch pack, follow the installation instruction sheet included in the service kit.

3L1Z-4947-AB (9.75" limited slip)
3L1Z-4947-BC (8.8" limited slip)
NOTE: INSTALLING A CLUTCH PACK INTO AN INDEPENDENT REAR SUSPENSION (IRS) AXLE IS DIFFERENT FROM INSTALLING A CLUTCH PACK INTO A SOLID-BEAM AXLE. BE SURE TO FOLLOW THE INSTALLATION INSTRUCTION SHEET INCLUDED IN THE SERVICE KIT.



INSTALLATION TIPS

The clutch packs in this service kit DO NOT need to be shimmed. The clutch pack contains a pre-measured shim.
Be sure to install NEW circlips and halfshaft/wheel end nuts on IRS rear axle (not included in the service kit).
Soak the new clutch packs in Friction Modifier XL-3 (NOT XL-7) for fifteen (15) minutes prior to installation.
For IRS axle, Halfshaft Seal Protector 205-506 (included in the 2002 Explorer/Mountaineer Essential Tool Kit) must be used when removing the halfshafts to protect against seal damage, which may result in leaks.
Refill axles with 4 oz. Friction Modifier (XL-3) and the necessary amount of Rear Axle Lubricant XY-75W140-QL, regardless of the axle lubricant system originally used in the axle. Fill to capacity recommended in the Workshop Manual.
NOTE: AXLE FLUID REQUIREMENTS HAVE BEEN CHANGED. ALL VEHICLES BEING REPAIRED BY THIS TSB MUST HAVE REAR AXLE LUBE XY-75W140-QL INSTALLED, IN PLACE OF XY- 75W90-QFEHP. AS PART OF THIS REPAIR, CHECK AND REPLACE IF NECESSARY THE CURRENT XY-75W90-Q"FEHP" METAL TAG, WITH A NEW 75W140 TAG (F3TZ-4121-AA). ADDITIONALLY, REMOVE THE MULTI-COLORED LABEL WHICH IS LOCATED ON THE RIGHT SIDE AXLE TUBE, OR BLOCK OUT ANY/ALL "FEHP" OR "75W90" REFERENCES ON THE LABEL.



PART NUMBER PART NAME
3L1Z-4947-AB 9.75" RR Axle Clutch
3L1Z-4947-BC 8.8" RR Axle Clutch
XY-75W140-QL Rear Axle Lubricant
XL-3 Friction Modifier Additive
W710084-S439 Nut (Wheel End)
2L1Z-4B422-CA Circlips (for 9.75")
1L2Z-4B422-BA Circlips (for 8.8")



WARRANTY STATUS:
Eligible Under Provisions Of New Vehicle Limited Warranty Coverage