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Technical Q&A. HOW TO's, TSB's & Warranty Items Have a Problem? Technical Questions & Answers. HOW TO's & TSB's, Warranty Issues

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Old 12-10-2004, 11:23 AM   #26
03whitemach
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TSB Items

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
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Old 12-17-2004, 03:30 PM   #27
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TSB detail please

Does anyone have the detail on TSB # 04-5-3, Mar 04, A/C -Insturment Panel vents rattle?

For the past month or so since it's gotten cold, only at highway speeds, I get an intermittent "chirp" kind of rattle from the center of the dash. From the description of the TSB, this may be the same issue.

I have an appt. next week to take her in and gave the dealer the TSB # when I called for the appt., I'd just like to read the detail so I can go in prepared.

thanks in advance!!
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Old 04-19-2005, 04:55 PM   #28
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Re: Technical Service Bulletins (TSB's)

I am new to the board in addition to being a new Mach 1 owner. Purchased the car last Thursday...unfortunately it is in the dealership today getting work done on it. (MT - stalling when declerating in neutral & occasionally the Rpms do not decrease when clutch is engaged between third and fourth gear) After reading over this page and the website I discovered both problems are linked to the IAC Valve and MAS ( two abovementioned TSBs). This website is a wonderful resource and I wanted to express my thanks. Without it I would not be in an informed position when talking to the dealership about repairs. THANKS
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Old 04-30-2005, 02:28 AM   #29
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Re: Technical Service Bulletins (TSB's)

Is there any kind of new TSB out about the tick that includes the 04's? I heard from the cobra guys there was something being done for us.
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Old 04-30-2005, 08:21 PM   #30
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Re: Technical Service Bulletins (TSB's)

Heres the latest from Alldata:

04-24-8 041213 Steering - Squeak/Creak Noise on Turns
04-24-3 041213 Steering - Leather Coming Loose From Steering Wheel
04-24-20 041213 Drivetrain - L/S rear Axle Shudder/Chatter
04-24-21 041213 Restraint System - Seat Belts Slow to retract
04-19-8 040922 M/T - Hard To Shift Into 1st or Reverse When Stopped
04-15-6 040809 M/T - TR36550 5spd Jumps Out of Gear/ Gear Clash
04-13-4 040612 M/T - T56 6 Speed Rattle Noise Or Difficult To Shift
04-5-3 040322 A/C - Instrument Panel Vents Rattle
04-1-2 040126 Interior - Headliner Sags in Rear
03-24-3 031208 A/T - Shift Lever Stuck in PARK Position/Loose Knob
03-22-1 031110 Body - Hood Scoop Rattles
03-20-3 031013 Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
03-11-4 030609 Engine - Left Hand Side Ticking Noise
03-9-5 030512 Suspension - Rear Suspension Clunk/Pop Noise
03-1-5 030120 Interior - Passenger Seat Squeaking Sound
02-22-1 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set
02-17-8 020902 Interior - 'A' Pillar Area Wind Noise
02-17-6 020902 A/T - Inadvertent Shift Interlock Disabling

If you need details let me know, I have a subscription.

Cheers
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Old 04-30-2005, 10:20 PM   #31
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Re: Technical Service Bulletins (TSB's)

subscribing
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Old 05-05-2005, 06:28 PM   #32
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Re: Technical Service Bulletins (TSB's)

Found the TSP for the squeaking vent panels #04-5-3. Basically it requires a revised vent (3R3Z-19893-AB) and its a 20 minute fix. They simply pry out the original vent with a screwdriver and pop in the new one.

I also found TSP 04-24-21 that deals with slow seat belt retraction speed. It calls for teflon tape to be added and looks to be a 2 1/2 hour job as the seats may need to be removed. Mine takes forever to coil up when I remove it and I plan on getting it fixed at the same time I get the vent replaced and my power steering gear tube bracket from TSP 04-24-8. Seems like Ford has finally caught up to my problems!
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Old 05-05-2005, 06:39 PM   #33
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Re: Technical Service Bulletins (TSB's)

sounds like I'm getting a new head . I have the noise (tick) exactly as described in the TSB. The car is going to the dealer as soon as I get back from Dallas next week.
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Old 05-15-2005, 11:49 PM   #34
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Re: Technical Service Bulletins (TSB's)

I remember a while back people having issues with the lower ball joints popping or crunching. Was that issue different from the one covered in 04-24-8?

I get some noise when I turn, but its a lot worse accelerating from and decelerating to a stop and when I go over bumps, especially speed bumps. It's to the point where it is embarassing to drive the car thru a parking lot.
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Old 05-16-2005, 12:26 AM   #35
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Re: Technical Service Bulletins (TSB's)

Quote:
Originally Posted by TwinCam
I remember a while back people having issues with the lower ball joints popping or crunching. Was that issue different from the one covered in 04-24-8?

I get some noise when I turn, but its a lot worse accelerating from and decelerating to a stop and when I go over bumps, especially speed bumps. It's to the point where it is embarassing to drive the car thru a parking lot.
04-24-8 is for a creaking type sound when turning the steering wheel when stopped or at very slow speeds, theres a ssm about a crunching noise when braking and going over speed bumps as you are describing.

Heres the ssm info

SSM 17100

2003-2004 Mustang - Front Suspension Noise

Some 2003-2004 Mustangs may exhibit a squeaking or crunching noise from the front suspension while driving over bumps or braking. This may be caused by the lower control arm bushings. To service, replace both lower control arms per workshop manual section 204-01. For LX vehicles, replace with XR3Z-3078-AA (Right Side) and XR3Z-3079-AA (Left Side). For GT vehicles, replace with XR3Z-3078-BA (Right Side) and XR3Z-3079-BA (Left Side). For Cobra/Mach vehicles, replace with 2R3Z-3078-AA (Right Side) and 2R3Z-3079-AA (Left Side). After replacing the control arms, check aligment and adjust if necessary. Verify that the noise is eliminated.

Symptom Code on Ford's OASIS is under 30400-Chassis Suspension System
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Old 05-18-2005, 07:34 PM   #36
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Re: Technical Service Bulletins (TSB's)

Thanks for the info 2k4mach. Is there a TSB or SSM for problems with auto trannies. The Mach's tranny shifts into 3 and 4 with converter locked are getting kind of bad. The best way to describe it is a shudder.

Personally, I think that the tranny is shifting too fast and the motor doesn't like it. Kind of like the clutch slipping and the tranny bucking if you shift from 1st to 4th on a manual when engine RPMs are too low. However, the issue wasn't present when the car was new and the symptom is getting worse with the passage of time. THe Mach is daily driven by the wife (not a hot rodding bone in her body) and only has 17,000 miles on it.
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JLT True Ram Air Intake Kit
Flowmaster Mufflers

DynoJet results: 246 HP / 258 FT-LBS SAE, BONE STOCK

currently own: fully restored (13 years in the making) '69 Camaro, 500 hp Procharged 350, Tremec TKO; Shown in Hot Rod Magazine 11/03 (page 50) visit my website at http://www.geocities.com/gheatly for pics.

previously owned: 1991 GT 5-sp hatchback, '91 GT 5-sp convertible

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Old 05-19-2005, 03:33 PM   #37
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Re: Technical Service Bulletins (TSB's)

03-9-5 030512 Suspension - Rear Suspension Clunk/Pop Noise

Does anyone have more info on this one? I've heard this several times... but it says Cobra only. Thanks!!!

Quote:
Originally Posted by 03greymach1
Heres the latest from Alldata:

04-24-8 041213 Steering - Squeak/Creak Noise on Turns
04-24-3 041213 Steering - Leather Coming Loose From Steering Wheel
04-24-20 041213 Drivetrain - L/S rear Axle Shudder/Chatter
04-24-21 041213 Restraint System - Seat Belts Slow to retract
04-19-8 040922 M/T - Hard To Shift Into 1st or Reverse When Stopped
04-15-6 040809 M/T - TR36550 5spd Jumps Out of Gear/ Gear Clash
04-13-4 040612 M/T - T56 6 Speed Rattle Noise Or Difficult To Shift
04-5-3 040322 A/C - Instrument Panel Vents Rattle
04-1-2 040126 Interior - Headliner Sags in Rear
03-24-3 031208 A/T - Shift Lever Stuck in PARK Position/Loose Knob
03-22-1 031110 Body - Hood Scoop Rattles
03-20-3 031013 Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
03-11-4 030609 Engine - Left Hand Side Ticking Noise
03-9-5 030512 Suspension - Rear Suspension Clunk/Pop Noise
03-1-5 030120 Interior - Passenger Seat Squeaking Sound
02-22-1 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set
02-17-8 020902 Interior - 'A' Pillar Area Wind Noise
02-17-6 020902 A/T - Inadvertent Shift Interlock Disabling

If you need details let me know, I have a subscription.

Cheers
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Old 05-19-2005, 09:52 PM   #38
03greymach1
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Re: Technical Service Bulletins (TSB's)

The TSB is at the beginning of this thread... see the PDF file for details.

Quote:
Originally Posted by RedMach1_04
03-9-5 030512 Suspension - Rear Suspension Clunk/Pop Noise

Does anyone have more info on this one? I've heard this several times... but it says Cobra only. Thanks!!!
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Old 05-20-2005, 09:54 AM   #39
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Re: Technical Service Bulletins (TSB's)

I saw the TSB at the beginning, thanks. But I was curious if anyone has any info about it being on a Mach1 (new TSB)? It says cobra only.

Thanks.

Quote:
Originally Posted by 03greymach1
The TSB is at the beginning of this thread... see the PDF file for details.
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Old 05-20-2005, 06:30 PM   #40
03greymach1
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Re: Technical Service Bulletins (TSB's)

I have a noise from the suspension coming from the rear and the front.

Did you see this:

04-24-8 is for a creaking type sound when turning the steering wheel when stopped or at very slow speeds, theres a ssm about a crunching noise when braking and going over speed bumps as you are describing.

Heres the ssm info

SSM 17100

2003-2004 Mustang - Front Suspension Noise

Some 2003-2004 Mustangs may exhibit a squeaking or crunching noise from the front suspension while driving over bumps or braking. This may be caused by the lower control arm bushings. To service, replace both lower control arms per workshop manual section 204-01. For LX vehicles, replace with XR3Z-3078-AA (Right Side) and XR3Z-3079-AA (Left Side). For GT vehicles, replace with XR3Z-3078-BA (Right Side) and XR3Z-3079-BA (Left Side). For Cobra/Mach vehicles, replace with 2R3Z-3078-AA (Right Side) and 2R3Z-3079-AA (Left Side). After replacing the control arms, check aligment and adjust if necessary. Verify that the noise is eliminated.

Symptom Code on Ford's OASIS is under 30400-Chassis Suspension System

She's going in Tuesday for a demo for the service manager!
Quote:
Originally Posted by RedMach1_04
I saw the TSB at the beginning, thanks. But I was curious if anyone has any info about it being on a Mach1 (new TSB)? It says cobra only.

Thanks.
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Old 06-02-2005, 12:11 AM   #41
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Re: Technical Service Bulletins (TSB's)

[QUOTE=03greymach1]I have a noise from the suspension coming from the rear and the front.

I have a load of creaking and groaning coming out of the rear end...i.e. suspension, sway bars, something in the back end. It sounds like an old clunker car. Whenever I roll over an uneven area, i.e. pavement higher on the left than the right. I guess something is either too tight, or too loose. Maybe some bushings are doing this? Help... anybody tackle this one yet? If so, what did Ford do to fix it. I don't want them farting around on my car for two weeks trying to figure it out.
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Old 07-08-2005, 12:08 PM   #42
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Re: Technical Service Bulletins (TSB's)

If anyb need the TSB pls post or pm me.

Technical Service Bulletins
2003 MUSTANG - US (English)

05-9-18
DISCHARGED BATTERY - CHARGING SERVICE TIPS
05-3-10
SAFETY BELT WEB STOP BUTTON SERVICE
04-24-21
SAFETY BELT RETRACTION SPEED
04-24-20
LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNING MANEUVERS
04-24-14
GENERAL PCM PROGRAMMING PROCEDURES
04-24-8
STEERING RACK NOISE
04-24-5
REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR
04-24-3
LEATHER-WRAPPED STEERING WHEEL - LEATHER COMING LOOSE
04-21-6
EXHAUST LEAK - CRACKED OR SEPARATED RIGHT SIDE EXHAUST PIPE - 3.8L AND 3.9L ENGINES
04-19-8
MANUAL TRANSMISSION HARD TO SHIFT INTO FIRST/REVERSE FROM A STOP
04-17-4
MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - SYSTEM LEAN DIAGNOSTIC TROUBLE CODES (DTC'S) - SERVICE TIPS
04-16-1
ENGINE MISFIRE OR ROUGH RUNNING - COIL ON PLUG (COP) IGNITION SYSTEMS - WDS COP KIT DIAGNOSTIC TIPS
04-15-6
TR3650 MANUAL TRANSMISSION - JUMPS OUT OF GEAR 2ND AND/OR 3RD - CLASH NOISE AND/OR RASPY FEEL ON GEAR ENGAGEMENT
04-13-4
TRANSMISSION RATTLE NOISE OR DIFFICULT TO SHIFT - TREMEC T56 6 SPEED MANUAL
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
03-25-6
ENGINE - ROMEO BUILT 4.6L 2V - TICK NOISE FROM ENGINE - ENGINES BUILT BEFORE 9/17/2003
03-25-5
PAINT - PIN HOLES AND/OR PAINT DELAMINATION ON VEHICLE HOOD - VEHICLES BUILT 6/1/2001 THROUGH 3/1/2003 ONLY
03-24-3
TRANSMISSION - AUTOMATIC TRANSMISSION GEAR SELECTOR LEVER STUCK IN PARK, UNABLE TO SHIFT INTO PARK - OVERDRIVE FUNCTION INOPERATIVE
03-23-2
BODY - MIRROR - EXTERIOR MIRROR GLASS AND MOTOR REPLACEMENT - SERVICE TIPS
03-22-1
BODY - NOISE - HOOD SCOOP (SHAKER) RATTLE NOISE
ENGINE - NOISE - HOOD SCOOP (SHAKER) RATTLE NOISE
NOISE - HOOD SCOOP (SHAKER) RATTLE NOISE
03-20-3
DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457
03-18-1
ELECTRICAL - REMOTE KEYLESS ENTRY (RKE) - SERVICE TIPS
03-14-8
TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS
03-11-6
ELECTRICAL - WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS
03-11-4
ENGINE - MUSTANG COBRA - TICK NOISE FROM ENGINE - COBRA VEHICLES EQUIPPED WITH ENGINES BUILT BEFORE 11/1/2002 ONLY
03-10-1
PAINT - PLASTIC BUMPER/FASCIA PARTS - PREPARATION PROCEDURES - SERVICE TIPS
03-9-5
SUSPENSION - CLUNK OR POP NOISE FROM REAR SUSPENSION - MUSTANG COBRA ONLY - SERVICE TIPS
NOISE - CLUNK OR POP NOISE FROM REAR SUSPENSION - MUSTANG COBRA ONLY - SERVICE TIPS
03-8-3
ENGINE - ENGINE OIL LEVEL INDICATOR MARKINGS - REPORTS OF LOW OIL LEVELS
03-3-6
SUSPENSION - DRIFT OR PULL TO RIGHT OR LEFT - MUSTANG COBRA MODELS ONLY
03-1-5
TRIM - PASSENGER SEAT RUBS AGAINST DOOR PANEL
02-23-7
COOLING SYSTEM - MOTORCRAFT PREMIUM GOLD ENGINE COOLANT - SERVICE TIPS
02-23-3
DRIVEABILITY - FUEL PRESSURE RELIEF VALVE (SCHRADER VALVE) DISCONTINUED
ENGINE - 3.0L/3.8L/4.6L - FUEL PRESSURE RELIEF VALVE (SCHRADER VALVE) DISCONTINUED
02-22-1
DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION
ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION
02-21-13
ENGINE - STRAIGHTEDGE PROCEDURE FOR CHECKING CYLINDER HEAD AND BLOCK FLATNESS
02-20-8
CLIMATE CONTROL - A/C SERVICE TECH TIPS
02-17-8
NOISE - WINDNOISE FROM THE "A" PILLAR AREA
02-17-6
LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK
02-16-7
BODY - PAINT - APPROVED PAINT MATERIALS FOR WARRANTY REPAIRS



TSB UPDATE as June 25, 2005 for 04 MACH1

Technical Service Bulletins
2004 MUSTANG - US (English)


05-9-18
DISCHARGED BATTERY - CHARGING SERVICE TIPS
05-9-3
INTERIOR PLASTIC TRIM - PAINT-TO-MATCH AND REPAIR - INTERIOR SPRAY PAINT AND ADHESION PROMOTER USAGE INSTRUCTIONS
05-3-10
SAFETY BELT WEB STOP BUTTON SERVICE
04-26-13
1-2 SHIFT CLASH, GRIND OR HARD TO SHIFT - TR3650 5 SPEED MANUAL TRANSMISSION
04-24-21
SAFETY BELT RETRACTION SPEED
04-24-20
LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNING MANEUVERS
04-24-14
GENERAL PCM PROGRAMMING PROCEDURES
04-24-8
STEERING RACK NOISE
04-24-5
REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR
04-24-3
LEATHER-WRAPPED STEERING WHEEL - LEATHER COMING LOOSE
04-21-6
EXHAUST LEAK - CRACKED OR SEPARATED RIGHT SIDE EXHAUST PIPE - 3.8L AND 3.9L ENGINES
04-19-8
MANUAL TRANSMISSION HARD TO SHIFT INTO FIRST/REVERSE FROM A STOP
04-17-4
MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - SYSTEM LEAN DIAGNOSTIC TROUBLE CODES (DTC'S) - SERVICE TIPS
04-16-1
ENGINE MISFIRE OR ROUGH RUNNING - COIL ON PLUG (COP) IGNITION SYSTEMS - WDS COP KIT DIAGNOSTIC TIPS
04-13-4
TRANSMISSION RATTLE NOISE OR DIFFICULT TO SHIFT - TREMEC T56 6 SPEED MANUAL
04-9-6
BODY - PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION
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
03-25-6
ENGINE - ROMEO BUILT 4.6L 2V - TICK NOISE FROM ENGINE - ENGINES BUILT BEFORE 9/17/2003
03-23-2
BODY - MIRROR - EXTERIOR MIRROR GLASS AND MOTOR REPLACEMENT - SERVICE TIPS
03-22-1
BODY - NOISE - HOOD SCOOP (SHAKER) RATTLE NOISE
ENGINE - NOISE - HOOD SCOOP (SHAKER) RATTLE NOISE
NOISE - HOOD SCOOP (SHAKER) RATTLE NOISE
03-18-1
ELECTRICAL - REMOTE KEYLESS ENTRY (RKE) - SERVICE TIPS
__________________
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http://www.mach-1.org/photopost/data...gchop.jpg?6184
03 zinc yellow mach 1
292 rwh 318.2 rwt (XPIPE/XCAL2)
iup/astra louvers/short ant./k&nfipk/bassani offroad x/sct xcal 2/powdercoated wheels/interior dressup/15% tint..
1 of 869
born 06/13/03 (thanks donna)
that is a friday the 13th should I be
worried
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Old 07-11-2005, 11:40 AM   #43
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Re: Technical Service Bulletins (TSB's)

LEATHER-WRAPPED STEERING WHEEL—LEATHER TSB 04-24-3
COMING LOOSE
FORD: LINCOLN:
2000-2004 Crown Victoria, Mustang 2000-2002 Continental
3. Apply Motorcraft Instant Gel Adhesive (TA-19) ISSUE
evenly over the wheel spoke. Some vehicles with leather-wrapped steering wheels
may exhibit the leather coming loose from the 4. Fold the leather back into its original position.
spoke area.
5. Smooth the leather, tuck in for neat
ACTION appearance, and apply pressure until the
Apply Motorcraft Instant Gel Adhesive to re-adhere leather is bonded to the wheel spoke (apply
the loose leather to the wheel spoke. Refer to the pressure for at least 30 seconds).
following Service Procedure.
NOTE
SERVICE PROCEDURE THE ADHESIVE SHOULD BE COMPLETELY SET
AFTER 5 MINUTES. DO NOT PULL ON THE NOTE
REPAIR AREA.
IF RE-ADHERING LEATHER TO THE FRONT
SIDE OF THE STEERING WHEEL ONLY, OMIT 6. Reinstall steering wheel.
STEPS 1 AND 6. STEERING WHEEL/AIRBAG
ASSEMBLY REMOVAL IS NECESSARY ONLY PART NUMBER PART NAME
WHEN REPAIRING LOOSE LEATHER ON THE TA-19 Motorcraft Instant Gel Adhesive
BACKSIDE OF THE STEERING WHEEL.
WARRANTY STATUS: Eligible Under Provisions Of CAUTION
New Vehicle Limited AVOID SKIN CONTACT WITH TA-19 ADHESIVE.
Warranty Coverage
1. Remove the steering wheel (ONLY DEALER CODING
NECESSARY TO REPAIR BACKSIDE OF CONDITION
STEERING WHEEL). Refer to Workshop BASIC PART NO. CODE
Manual Sections 211-04 and 501-20B. 3600 33
2. Fold loose leather out of the way.

SAFETY BELT RETRACTION SPEED TSB 04-24-21
FORD: LINCOLN:
2000-2004 Mustang PART APPLICATION CHART ISSUE
Part Number Application A service kit is now available to improve safety belt
retraction speed. YR3Z-63611D70-AA MUSTANG
ACTION XW4Z-63611D70-AA LINCOLN LS
XW4Z-63611D70-AA E-SERIES See the part application chart and select the
appropriate kit. Follow the Instruction Sheet included
3L2Z-78611D70-AB CONTINENTAL in the kit. Refer to Workshop Manual Section 3L2Z-78611D70-AB CROWN VICTORIA
501-20a for additional information. 3L2Z-78611D70-AB EXPEDITION
3L2Z-78611D70-AB EXPLORER SPORT
NOTE 3L2Z-78611D70-AB EXPLORER SPORT TRAC
3L2Z-78611D70-AB EXCURSION IF TEFLON TAPE IS ALREADY PRESENT ON
3L2Z-78611D70-AB ESCAPE THE SAFETY BELT GUIDE RING (D-RING), DO
3L2Z-78611D70-AB ESCAPE HYBRID NOT CONTINUE WITH THIS TSB. 3L2Z-78611D70-AB FREESTAR
3L2Z-78611D70-AB F-SERIES SUPER DUTY NOTE 3L2Z-78611D70-AB F-150
EACH KIT SERVICES TWO (2) BELTS. 3L2Z-78611D70-AB F650/F750
3L2Z-78611D70-AB GRAND MARQUIS
NOTE 3L2Z-78611D70-AB MARINER
3L2Z-78611D70-AB MONTEREY DOES NOT APPLY TO AVIATOR/EXPLORER
3L2Z-78611D70-AB NAVIGATOR 4DR/MOUNTAINEER FRONT SAFETY BELTS FOR
3L2Z-78611D70-AB RANGER VEHICLES BUILT AFTER 6/25/2004, OR REAR 3L2Z-78611D70-AB SABLE
SAFETY BELTS FOR VEHICLES BUILT AFTER 3L2Z-78611D70-AB TAURUS
10/22/2004, BECAUSE TEFLON TAPE IS 3L2Z-78611D70-AB TOWN CAR
3L2Z-78611D70-AB WINDSTAR INSTALLED DURING PRODUCTION.
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.
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 04-24-21 (Continued)
WARRANTY STATUS: Eligible Under Provisions Of 042421C Install Teflon Tape D 0.7 Hr.
New Vehicle Limited Pillars Both Sides
Warranty Coverage (Includes Time To Remove
OPERATION DESCRIPTION TIME And Install Trim Panels If
042421A Install Teflon Tape B 0.8 Hr. Necessary)
Pillars Both Sides DEALER CODING
(Includes Time To Remove CONDITION
And Install Trim Panels If BASIC PART NO. CODE
Necessary) 70611D70 41
042421B Install Teflon Tape C 1.1 Hrs.
Pillars Both Sides
(Includes Time To Remove
And Install Trim Panels
And Seats If Necessary)
PAGE 2

• BODY—NOISE—HOOD SCOOP (SHAKER) RATTLE Article No.
NOISE 03-22-1
• ENGINE—NOISE—HOOD SCOOP (SHAKER)
RATTLE NOISE
• NOISE—HOOD SCOOP (SHAKER) RATTLE NOISE
FORD: 2003-2004 MUSTANG
NOTE ISSUE
USING A SCREWDRIVER TO HELP GUIDE THE Some 2003-2004 Mustang Mach 1 may exhibit a
EDGE OF THE ISOLATOR INTO THE HOLE MAY rattle type noise from the Hood Scoop (Shaker)
DAMAGE THE MATERIAL OF THE ISOLATOR. area. The noise may occur at any engine RPM
and/or during acceleration or deceleration.
5. Once the entire outer edge is within the hole,
push the isolator down into the hole. ACTION
To service, install revised Hood Scoop Isolators 6. Reinstall the Hood Scoop.
(four), part number (2L7Z-9P686-AA). Refer to the
7. Verify the condition is corrected. following Service Procedure.
SERVICE PROCEDURE PART NUMBER PART NAME
2L7Z-9P686-AA Isolator 1. Remove the Hood Scoop per the Workshop
Manual (Section 303-12).
OTHER APPLICABLE ARTICLES: NONE
2. Place the Hood Scoop upside down on the WARRANTY STATUS: Eligible Under Provisions Of
workbench. New Vehicle Limited
Warranty Coverage NOTE
OPERATION DESCRIPTION TIME
PLACE HOOD SCOOP ON A CLOTH TO
032201A Install Revised Hood 0.7 Hr. PREVENT SCRATCHING OR MARRING OF THE
Scoop Isolators (Includes FINISH.
Time To Remove And
Install Hood Scoop) 3. Remove the four (4) isolators by grasping with
your fingers and pulling up and towards the
center of the isolator (Figure 1).
4. Install new Isolators (2L7Z-9P686-AA) by
setting the isolator in the hole at an angle
(Figure 2) and pressing down, while working
the outer edge of the isolator down into the
hole with your fingers.
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.
Copyright ã 2003 Ford Motor Company PAGE 1
Article No. 03-22-1 Cont’d.
DEALER CODING
CONDITION
BASIC PART NO. CODE
6N079 07
Figure 1 - Article 03-22-1
Figure 2 - Article 03-22-1
PAGE 2


• SUSPENSION—CLUNK OR POP NOISE FROM Article No.
REAR SUSPENSION—MUSTANG COBRA ONLY— 03-9-5
SERVICE TIPS
• NOISE—CLUNK OR POP NOISE FROM REAR
SUSPENSION—MUSTANG COBRA ONLY—SERVICE
TIPS
FORD: 1999-2003 MUSTANG
ISSUE OTHER APPLICABLE ARTICLES: NONE
Some 1999-2003 Mustang Cobra vehicles may WARRANTY STATUS: INFORMATION ONLY
exhibit a “popping” type noise while turning into or OASIS CODES: 304000, 305000, 390000, 702000,
out of an incline, such as turning into a driveway, at 702200
low speeds (below 15 mph (25 km/h). The steeper
the incline the more noticeable the noise will be.
This may be caused by the lateral movement of the
stabilizer bar or one or more of the fasteners shown
in Figures 1-3, that may not be tightened within the
required torque specifications.
ACTION
Inspect and torque all of the fasteners listed for the
proper torque. Refer to the following Service
Information for details.
SERVICE INFORMATION
Raise vehicle on hoist and verify torque at the
following components and locations:
• Stabilizer bar bracket bolts (both sides) (Figure 1)
- 42.8 ± 3.7 Lb-ft. (58 ± 5 N•m)
• Stabilizer bar collar bolts (both sides) (Figure 1) -
6.6 ± 1.0 Lb-ft. (9 ± 1.4 N•m)
• Lower shock bolts (both sides) (Figure 2) - 98.1 ±
14.8 Lb-ft. (133 ± 20 N•m)
• Upper control arm bushing bolts (both sides)
(Figure 3) - 66.4 ± 10.0 Lb-ft. (90 ± 13.5 N•m)
• Stabilizer bar link bolts (both sides) (Figure 3) -
35.0 ± 5.3 Lb-ft. (47.5 ± 7.2 N•m)
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.
Copyright ã 2003 Ford Motor Company PAGE 1
Article No. 03-9-5 Cont’d.
Figure 1 - Article 03-9-5
PAGE 2
Article No. 03-9-5 Cont’d.
Figure 2 - Article 03-9-5
Figure 3 - Article 03-9-5
PAGE 3

LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING TSB 04-24-20
SENSATION, OR VIBRATION DURING LOW SPEED
TURNING MANEUVERS
FORD: LINCOLN:
2002-2005 Crown Victoria, Mustang, This article supersedes TSB 04-17-5 to update the • 3L1Z-4947-BC (8.8² limited slip)
model year and vehicle line coverage.
NOTE
INSTALLING A CLUTCH PACK INTO AN ISSUE
INDEPENDENT REAR SUSPENSION (IRS) AXLE Some 2003-2005 Expedition/Navigator, 2004-2005
IS DIFFERENT FROM INSTALLING A CLUTCH F-150 vehicles equipped with a 9.75² or 8.8²
PACK INTO A SOLID-BEAM AXLE. BE SURE TO limited slip rear axle, and 2002-2005 Explorer 4dr,
FOLLOW THE INSTALLATION INSTRUCTION Mountaineer, Crown Victoria, Grand Marquis, Town
SHEET INCLUDED IN THE SERVICE KIT. Car, and Mustang vehicles equipped with 8.8²
limited slip rear axle, may exhibit a chatter, INSTALLATION TIPS
shudder, a binding sensation, or a vibration during
• The clutch packs in this service kit DO NOT need low speed turns. On 4x4 vehicles, the sensation
to be shimmed. The clutch pack contains a may appear to be originating from the front axle or
pre-measured shim. the steering gear.
• Be sure to install NEW circlips and
ACTION halfshaft/wheel end nuts on IRS rear axle (not
First verify the condition. On 4x4 trucks ensure that included in the service kit).
the vehicle is in 2WD, to isolate the rear axle. On • Soak the new clutch packs in Friction Modifier
all vehicles, turn the wheel fully right (or fully left) XL-3 (NOT XL-7) for fifteen (15) minutes prior to
and then accelerate the vehicle. If the condition is installation.
verified to be in the rear axle, replace the limited
• For IRS axle, Halfshaft Seal Protector 205-506 slip clutch pack.
(included in the 2002 Explorer/Mountaineer
Essential Tool Kit) must be used when removing SERVICE PROCEDURE
the halfshafts to protect against seal damage,
CAUTION which may result in leaks.
INSTRUCT THE CUSTOMER NOT TO TOW WITH • Refill axles with 4 oz. Friction Modifier (XL-3) and
THE VEHICLE FOR 500 MILES AFTER THIS the necessary amount of Rear Axle Lubricant
REPAIR, TO ALLOW THE AXLE TO BREAK-IN XY-75W140-QL, regardless of the axle lubricant
PROPERLY. system originally used in the axle. Fill to capacity
recommended in the Workshop Manual. Order and install the appropriate clutch pack, follow
the installation instruction sheet included in the
service kit.
• 3L1Z-4947-AB (9.75² limited slip)
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 04-24-20 (Continued)
NOTE 042420D F-150: Replace Clutch 3.0 Hrs.
Pack (Includes Time For AXLE FLUID REQUIREMENTS HAVE BEEN
Road Test To Verify CHANGED. ALL VEHICLES BEING REPAIRED BY
Concern, Replace Rear THIS TSB MUST HAVE REAR AXLE LUBE
Clutch Pack, And Re-Road XY-75W140-QL INSTALLED, IN PLACE OF XYTest)
75W90-QFEHP. AS PART OF THIS REPAIR,
042420E Crown Victoria/Grand 3.0 Hrs. CHECK AND REPLACE IF NECESSARY THE
Marquis, Town Car: CURRENT XY-75W90-Q“FEHP” METAL TAG, WITH
Replace Clutch Pack A NEW 75W140 TAG (F3TZ-4121-AA).
(Includes Time For Road ADDITIONALLY, REMOVE THE MULTI-COLORED
Test To Verify Concern, LABEL WHICH IS LOCATED ON THE RIGHT SIDE
Replace Rear Clutch Pack, AXLE TUBE, OR BLOCK OUT ANY/ALL “FEHP”
And Re-Road Test) OR “75W90” REFERENCES ON THE LABEL.
042420F 2002-2004 Mustang: 2.9 Hrs.
PART NUMBER PART NAME Replace Clutch Pack
(Includes Time For Road 3L1Z-4947-AB 9.75² RR Axle Clutch
Test To Verify Concern, 3L1Z-4947-BC 8.8² RR Axle Clutch
XY-75W140-QL Rear Axle Lubricant Replace Rear Clutch Pack,
XL-3 Friction Modifier Additive And Re-Road Test)
W710084-S439 Nut (Wheel End) 042420G 2005 Mustang: Replace 3.4 Hrs. 2L1Z-4B422-CA Circlips (for 9.75²)
Clutch Pack (Includes 1L2Z-4B422-BA Circlips (for 8.8²)
Time For Road Test To
Verify Concern, Replace WARRANTY STATUS: Eligible Under Provisions Of
Rear Clutch Pack, And New Vehicle Limited
Re-Road Test) Warranty Coverage
042420H Mustang Cobra: Replace 5.6 Hrs. OPERATION DESCRIPTION TIME
Clutch Pack (Includes 042420A Expedition Without Air 4.2 Hrs.
Time For Road Test To Suspension: Replace
Verify Concern, Replace Clutch Pack (Includes
Rear Clutch Pack, And Time For Road Test To
Re-Road Test) Verify Concern, Replace
DEALER CODING Rear Clutch Pack, And
CONDITION Re-Road Test)
BASIC PART NO. CODE 042420B Expedition/Navigator With 4.4 Hrs.
4947 D4 Air Suspension: Replace
Clutch Pack (Includes
Time For Road Test To
Verify Concern, Replace
Rear Clutch Pack, And
Re-Road Test)
042420C Explorer/Mountaineer: 4.6 Hrs.
Replace Clutch Pack
(Includes Time For Road
Test To Verify Concern,
Replace Rear Clutch Pack,
And Re-Road Test)



STEERING RACK NOISE TSB 04-24-8
FORD:
2002-2004 Mustang
WARRANTY STATUS: Eligible Under Provisions Of ISSUE
New Vehicle Limited Some 2002-2004 Mustang vehicles may exhibit a
Warranty Coverage squeak or creak type noise while turning.
OPERATION DESCRIPTION TIME
042408A Replace Power Steering 0.8 Hr. ACTION
Gear Tube Bracket Replace the power steering gear tube bracket. Use
DEALER CODING only replacement parts that have a green paint dot.
CONDITION Torque the fasteners to 52 lb-ft (70 N•m).
BASIC PART NO. CODE
PART NUMBER PART NAME 3K620 16
E5DZ-3K620-A Bracket
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

MALFUNCTION INDICATOR LAMP (MIL) TSB 04-17-4
ILLUMINATED—SYSTEM LEAN DIAGNOSTIC
TROUBLE CODES (DTC’S)—SERVICE TIPS
FORD: LINCOLN:
Mustang, NOTE ISSUE
FREEZE FRAME DATA WILL INDICATE THE This article is intended to aid in diagnosing DTC’s
ENGINE AND AMBIENT CONDITIONS WHEN THE P0171, P0174, P1130, P1131, P1150, P1151,
DTC WAS SET. THESE ARE IMPORTANT P2195, or P2197 (system lean or lack of HEGO
BECAUSE THE VACUUM LEAKS MAY OCCUR switches) when a vacuum leak is present. HEGO
ONLY WITHIN SPECIFIC TEMPERATURE sensors, MAF sensors, and PCM replacements are
RANGES AND MUST BE DUPLICATED TO not an effective repair when a vacuum leak is
DETECT THE LEAK. causing the above DTC’s.
NOTE ACTION
FUEL TRIMS AT IDLE ARE PARTICULARLY Perform the following inspections/repairs when the
SENSITIVE TO VACUUM LEAKS SINCE THE above codes are found in memory. Procedure
UN-METERED AIR “LEAKAGE FLOW” IS A provides instructions on how to make comparisons
HIGHER PERCENTAGE OF TOTAL AIRFLOW AT of the total fuel corrections (using scan tool or
IDLE THAN AT PART THROTTLE. THE equivalent) at idle and high RPM’s to help
BAROMETRIC PRESSURE (BP) PID IS NOT determine if a vacuum leak is the root cause of the
RECOMMENDED TO VIEW WHEN DIAGNOSING DTC’s.
A VACUUM LEAK. BP IS AN INFERRED PID
SERVICE PROCEDURE CALCULATED DURING HIGHER ENGINE LOADS.
NOTE 1. Perform preliminary inspection, retrieve and
record DTC’s and Freeze Frame Data. DO FREEZE FRAME AND ADAPTIVE FUEL VALUES
NOT PERFORM KAM RESET OR OBDII (ASSOCIATED WITH “LONGFT” PID) WILL NOT
RESET (CLEAR CODES) AT THIS TIME, BE AVAILABLE IF A KAM OR OBDII RESET WAS
ADAPTIVE FUEL TABLES MUST BE INTACT RECENTLY PERFORMED.
FOR THIS PROCEDURE.
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 04-17-4 (Continued)
a. If DTCs are continuous, or if other DTC’s or e. Determine total fuel correction at idle for an
drive symptoms are present other than at in-line 4 cylinder engine or bank 1 of a
idle, diagnose and repair those V-engine by adding LONGFT1 to SHRTFT1.
codes/symptoms first. Determine total fuel correction for bank 2 of
a V-engine, by adding LONGFT2 to
b. Perform visual inspection - look for SHRTFT2.
disconnected/broken/cracked vacuum hoses
especially near vacuum trees. Check PCV NOTE
elbows for cracks or loose connection. MAKE SURE ONLY THE CORRECT BANKS AND
Confirm vehicle has the correct PCV valve TRIMS ARE ADDED TOGETHER (DO NOT ADD
installed. If a suspect vacuum leak is found LONGFT1 TO LONGFT2 OR LONGFT1 TO
proceed to Step 4. SHRTFT2.)
• EXAMPLE 1: BANK1 LONG FUEL TRIM; NOTE
LONGFT1 = +13% AND SHORT FUEL TRIM; EACH VEHICLE APPLICATION REQUIRES A PCV
SHRTFT1 = +23%. THE TOTAL CORRECTION VALVE CALIBRATED FOR THAT VEHICLE.
ON BANK1 IS +36% (13%+23%=36%). MOTORCRAFT PARTS ARE STRONGLY
• EXAMPLE 2: BANK2 LONGFT2 = +24% AND RECOMMENDED. ALSO, THERE WILL BE A
BANK 2 SHRFT2 = -3%. THIS TOTAL FUEL NORMAL VARIATION IN FUEL TRIMS FROM
CORRECTION ON BANK 2 IS +21% (+24% VEHICLE TO VEHICLE.
-3%= +21%.).
2. Determine if vacuum leak is present. A TYPICAL VACUUM LEAK WHICH MAY SET A
LEAN CODE DTC WILL HAVE TOTAL
a. Set up scan tool to monitor the following
CORRECTION OF AROUND +20% OR GREATER
PIDS: ECT/CHT, LONGFT1, LONGFT2,
AT OR NEAR IDLE (DEPENDS ON CALIBRATION)
SHRTFT1, SHRTFT2, IAT.
f. Depress and hold throttle pedal to maintain
b. Start the engine and run at idle with all
an engine RPM of 2500.
accessories off - gear lever in Neutral/Park.
g. Observe PIDS with engine RPM at 2500.
c. Run engine until ECT/CHT matches the
View and record LONGFT1, LONGFT2,
corresponding freeze frame data from Step
SHRTFT1, SHRTFT2. Do not hold engine
1. This will duplicate the customer’s engine
RPM’s at 2500 for more than 20 seconds.
operating temperatures when the DTC was
Release pedal and repeat if more time is
set in memory. Hood may remain open
necessary to record PIDS.
during this test to help reduce ECT/CHT/IAT
temperatures. Keep IAT below 115° F (46° h. Determine total fuel correction at 2500
C). RPM’s by adding the LONGFT’s to the
associated SHRTFT’s.
d. Record LONGFT’s and SHRTFT’s.
i. If the fuel correction decreases, more than NOTE
15%, (example: was +31% at idle on bank 1
TO PREVENT HIGH ECT/CHT AND IAT but changed to +12% at 2500RPM on bank
TEMPERATURES IT MAY BE NECESSARY TO 1, a decrease of 19%) then a vacuum leak
PERFORM THIS TEST WITH THE ENGINE is most likely causing the lean diagnostic
RUNNING FOR SHORT INTERVALS, ESPECIALLY test codes. Proceed to Step 3.
WHEN AMBIENT TEMPERATURE IS ABOVE 85° F
(29°C). USE OF A GARAGE FAN WILL HELP TO j. If the total correction remains approximately
KEEP ENGINE TEMPERATURES STABILIZED the same then the lean condition is not
DURING TEST. IT MAY BE NECESSARY TO RUN caused by a vacuum leak. Refer to the
THIS TEST AT SPECIFIC ECT/CHT/IAT PC/ED for further diagnostics.
TEMPERATURES, REVIEW FREEZE FRAME
3. Pinpointing vacuum leaks. DATA. EXAMPLE: IF ECT WAS AT 160° F (71° C)
THEN ENGINE MAY NEED A COLD START TO a. Monitor SHRTFT’s with scan tool with
DUPLICATE THIS TEMPERATURE. engine running at idle.
PAGE 2
TSB 04-17-4 (Continued)
b. Locate vacuum trees off air induction d. If vacuum leak is located proceed to Step
system and PCV system. Use hose clamp 4c.
or pinch off pliers (avoid tools with sharp
NOTE edges).
INTAKE GASKETS OR MANIFOLD LEAKS
NOTE CANNOT BE DETECTED BY PINCHING OFF
USE CAUTION WHEN CLAMPING HOSES. A LINES. USE OTHER LEAK DETECTION
VACUUM CAP OR EQUIVALENT CAN ALSO BE METHODS, SUCH AS SMOKE TEST, SONIC
USED TO BLOCK THE VACUUM SOURCE TO A TESTS, AND PROPANE.
SPECIFIC SYSTEM. DO NOT TRY TO PINCH OFF
e. If no vacuum leaks are found, refer to the A HARD PLASTIC HOSE OR CONNECTION, TRY
PC/ED for further diagnostics. ISOLATING BY CAPPING. CLAMPING OF THE
FUEL SYSTEM PURGE HOSE MAY SHIFT 4. Verification of repair.
SHRTFT DURING PURGING MODES, USE
VISUAL INSPECTION ON THIS HOSE IF a. Prepare scan tool and vehicle to monitor
RESULTS ARE NOT CONSISTENT. short term fuel trims (SHRTFT’s).
c. Observe short fuel trims when pinching b. Get vehicle into stabilized idle condition,
specific vacuum lines. The SHRTFT values unless freeze frame indicates other
should decrease more than 15% towards temperatures.
the negative direction, if a vacuum leak was
c. Repair vacuum leak. pinched off. (wait up to 20 seconds to
observe if pinch has any effect on d. SHRTFTs should decrease by at least 15%.
SHRTFT’s). If they do not, return to Step 2.
NOTE e. Clear KAM and codes.
EXAMPLE: PINCH OFF THE BRAKE BOOSTER
WARRANTY STATUS: Eligible Under Provisions Of VACUUM HOSE (DO THIS ONLY IN PARK) AND
New Vehicle Limited OBSERVE SHRTFT’S. IF THE SHRTFT’S
Warranty Coverage And DECREASES, BY MORE THAN 15%, A VACUUM
Emissions Warranty LEAK IS PRESENT. IF THE SHRTFT1 WAS AT
Coverage +14% BEFORE PINCHING THEN SHIFTS TO -7%
AFTER PINCHING, TOTAL SHIFT OF 21%
TOWARDS NEGATIVE DIRECTION.
__________________
I h8te rice
www.ricehatersclub.com
http://www.mach-1.org/photopost/data...gchop.jpg?6184
03 zinc yellow mach 1
292 rwh 318.2 rwt (XPIPE/XCAL2)
iup/astra louvers/short ant./k&nfipk/bassani offroad x/sct xcal 2/powdercoated wheels/interior dressup/15% tint..
1 of 869
born 06/13/03 (thanks donna)
that is a friday the 13th should I be
worried
www.perfectionperformance.com (my clubs website)
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Old 07-11-2005, 11:41 AM   #44
blazinsteed
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Re: Technical Service Bulletins (TSB's)

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
__________________
I h8te rice
www.ricehatersclub.com
http://www.mach-1.org/photopost/data...gchop.jpg?6184
03 zinc yellow mach 1
292 rwh 318.2 rwt (XPIPE/XCAL2)
iup/astra louvers/short ant./k&nfipk/bassani offroad x/sct xcal 2/powdercoated wheels/interior dressup/15% tint..
1 of 869
born 06/13/03 (thanks donna)
that is a friday the 13th should I be
worried
www.perfectionperformance.com (my clubs website)
blazinsteed is offline   Reply With Quote
Old 07-18-2005, 02:16 AM   #45
pdog2000
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Location: south beach, FL
Posts: 214
Re: Technical Service Bulletins (TSB's)

SGSCOMPS - i think it might be the "creak" see this one 04-24-8 DEC 04 Steering - Squeak/Creak Noise on Turns ...you can probably find it on the site somewhere or buy it http://www.alldata.com/TSB/19/041917e6.html

Donna - i had some problems with my AC clutch, it had to be replaced...i don't think there is a TSB...is the AC clutch engaging? you should be able to hear it...

good luck guys (and girls)
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Old 08-16-2005, 03:46 AM   #46
alex04mach1
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Re: Technical Service Bulletins (TSB's)

anyone has tsb on oil leak probably from transmission oil pump? that's what the dealer suspects.
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Old 10-01-2005, 12:39 PM   #47
03_shakur
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Re: Technical Service Bulletins (TSB's)

A MILLION thanks to ya! The Shaker/rattle noise just happened to my MACh1 this Friday night. So, I called the dealership and explained to them about the TSB for that issue. They said print it and bring it with the car we will cover the costs!!!
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Old 10-01-2005, 08:16 PM   #48
Red Mach'03
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Re: Technical Service Bulletins (TSB's)

Does anyone have the link for the one for stalling?
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Old 10-02-2005, 01:58 AM   #49
pdog2000
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Re: Technical Service Bulletins (TSB's)

man - i wish all dealers were that nice
Quote:
Originally Posted by 03_shakur
A MILLION thanks to ya! The Shaker/rattle noise just happened to my MACh1 this Friday night. So, I called the dealership and explained to them about the TSB for that issue. They said print it and bring it with the car we will cover the costs!!!
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2004 Azure Blue Mach 1
5-Speed IUP

Mods/Upgrades
Steeda Tri-Ax Shifter w/ gasket
Steeda Caster Camber Plates
Steeda G Trac Bar
Steeda 3 Point Strut Tower Brace
Steeda full length subframe connector (zinc plated)
K&N Filter
Bumper Inserts
Flaming Grille Pony
CobraJet Emblems
Autometer Tach, Oil, Water Gauges
Visteon Sirius Tuner
Bridgestone Potenza RE 01R (and they rock)
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Old 10-02-2005, 06:20 PM   #50
budnbwiserjr
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Re: Technical Service Bulletins (TSB's)

Does anybody know why the idle air control restrictor plates say for use on 5 speeds only? I'de like to get one but i have an automatic and was wondering if they will work on my car. Thanks for any info.
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