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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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12-10-2004, 10:23 AM | #26 |
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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 |
12-17-2004, 02:30 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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04-19-2005, 03:55 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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04-30-2005, 01:28 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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04-30-2005, 07:21 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 |
04-30-2005, 09:20 PM | #31 |
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Re: Technical Service Bulletins (TSB's)
subscribing
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05-05-2005, 05:28 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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05-05-2005, 05:39 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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05-15-2005, 10:49 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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05-15-2005, 11:26 PM | #35 | |
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Re: Technical Service Bulletins (TSB's)
Quote:
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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05-18-2005, 06:34 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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'03 Azure Blue, automatic 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 Hey, I can sit on the fence if I want to! |
05-19-2005, 02:33 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:
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05-19-2005, 08:52 PM | #38 | |
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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:
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05-20-2005, 08:54 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:
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05-20-2005, 05:30 PM | #40 | |
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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:
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06-01-2005, 11:11 PM | #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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07-08-2005, 11:08 AM | #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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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) |
07-11-2005, 10:40 AM | #43 |
MUSTANG ADDICT
Join Date: Oct 2003
Location: orlando fl
Posts: 2,471
|
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.
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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) |
07-11-2005, 10:41 AM | #44 |
MUSTANG ADDICT
Join Date: Oct 2003
Location: orlando fl
Posts: 2,471
|
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
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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) |
07-18-2005, 01:16 AM | #45 |
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Join Date: May 2004
Location: south beach, FL
Posts: 214
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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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nick 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) |
08-16-2005, 02:46 AM | #46 |
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Location: Hawaii
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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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10-01-2005, 11:39 AM | #47 |
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Join Date: Sep 2005
Location: Batavia, IL
Posts: 48
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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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2003, Black On Black Automatic, IUP K&N GEN II FIPK SLP Catted X-Pipe STEEDA - MIL Eliminators SLP LOUDMOUTH I Exhaust SUPER CHIPS MICRO TUNER BF Goodrich g-Force T/A KDWS Window Tint - 35% front / 20% rear 07-Summer Mods: 17" Black Cobra R wheels/chrome rivets /deep dish FRRP 4:10's |
10-01-2005, 07:16 PM | #48 |
mach madness
Join Date: Apr 2003
Location: Mifflintown PA
Posts: 663
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Re: Technical Service Bulletins (TSB's)
Does anyone have the link for the one for stalling?
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'03 Red mach 1 IUP Build Date 11/08/02 Received 4/03 Accessories Bassani s/s catback exhaust ceramic coated headers catted x pipe s/s Chrome peices on the engine, interior, cobra jet emblem on shaker, Chrome Bullit Wheels, Chrome valve stem caps, Blck letters to fill in Mustang,Coil Covers done by Kustom Machine, PHP Intake Sroud had it polished and removed snorkel. kick plates chrome ingraved mach 1 and Visor Louvers. |
10-02-2005, 12:58 AM | #49 | |
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Join Date: May 2004
Location: south beach, FL
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Re: Technical Service Bulletins (TSB's)
man - i wish all dealers were that nice
Quote:
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nick 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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10-02-2005, 05:20 PM | #50 |
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Join Date: Oct 2005
Location: Bristol, VA
Posts: 9
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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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