The below Technical Service Bulletins, TSB for short, were issued for the 1999 Mustang and contain symptom, diagnosis, and repair information for common issues. Click the TSB ID numbers below to see the full TSB, there is also a brief description of the TSB below the number.
Use this GSB to help determine (Warrantable / Non-Warrantable) Exterior Mirror defects vs. damage.
This GSB is designed to provide pictorial examples of paint defects / Damage to assist in the warrantable / non-warrantable determination. Refer to the latest version of the Warranty and Policy Manual for paint defect warranty coverage.
Some 1997-2008 vehicles equipped with a 4.6L 2V, 5.4L 2V, or 6.8L 2V engine and aluminum cylinder heads may experience a spark plug port with stripped or missing threads.
MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R).
MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the service fluid for manual transmissions originally requiring MERCON(R).
The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred.
On various vehicles when servicing the head gasket on certain Ford remanufactured engines, it is critical to determine the type of remanufactured engine that is being serviced, in order to identify the correct replacement gasket.
Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad.
Intake Manifold Extended Warranty Coverage
Approximately 50% of coil on plug (COP) coils returned for warranty do not have a problem.
Some vehicles may exhibit inoperative electric rear window defroster (heated back lite) grid lines, integral antenna concerns causing radio reception issues or terminal tabs pulled from the rear window glass.
PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed.
Some 1999-2004 Mustang vehicles equipped with a T5, T45 or TR3650 manual transmission, may exhibit a hard to shift condition into first or reverse gears from a stop. This may be due to an incomplete disengagement of the clutch (lack of clutch pedal reserve).
Should repairs become necessary on a 4R70W transmission involving replacement of the forward or reverse clutch sungear, and/or the number five (# 5) thrust bearing, these service pants all must be replaced in combination. A mismatch of service parts may cause an internal noise or a loss of forward and/or reverse. A new service kit has been produced to eliminate the mismatch of service pants. This new kit services all 4R70W transmissions built prior to the 2004 model.
When servicing an exterior mirror, service kits are available which enable repairs without replacement of the entire mirror assembly.
Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc.
Keyless Entry System - Service Tips
The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001.
Some vehicles equipped with the Romeo built 4.6L 2V engine or 5.4L 2V Windsor and 5.4L Supercharged engine may exhibit an oil leak or oil weepage from the cylinder head gasket at the right hand rear or the left hand front of the engine. Oil weepage is not considered detrimental to engine performance or durability. An oil leak may be caused by metal chip debris lodged between the head gasket and the block, chip debris between the cylinder head and the head gasket, or by damage to the cylinder head sealing surface that occurred during the manufacturing process.
Some vehicles may exhibit the passenger seat rubbing against the door panel or trim. This may result in a squeak type noise, especially in vehicles equipped with leather seating. This may be caused by the seat position in the vehicle.
NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured.
Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present.
Aluminum cylinder heads and blocks require flatness checks prior to gasket installation to ensure the component part is not out of factory specification. The surface quality (finish) of the cylinder head gasket surface is machined to close tolerances which enable an effective sealing joint for the MLS (multi-layered steel) gasket.
The following A/C tech tips are to assist the technician with the proper procedures for servicing A/C systems.
Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears.
Gasket removal, especially on multi-layered steel (MLS) head gaskets may leave behind a residue that is difficult to remove from the sealing surface. Effectively immediately, two new cleaning products are released to the field for use in removing gasket and oil residue from aluminum cylinder heads. These products are available and are recommended whenever a cylinder head is removed from the engine. The purpose of these cleaners is. to ensure a safe cleaning process is available which will not threaten the integrity of the sealing surface of the head.
Effective immediately, labor for the machining of head gasket surfaces on any engine fitted with aluminum heads will no longer be reimbursable under the provisions of the Warranty and Policy Manual (page 345 of the Oct. 2001 edition) of the Warranty and Policy Manual.
Some vehicles may exhibit an Intake Manifold crossover (first runner) coolant seepage condition. This may be caused by a crack in the Intake Manifold coolant crossover.
Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces.
Wheels/Tires - Road Force Measurement Equipment
Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles.
Reports of premature engine failure suggest some overhauled, new and/or remanufactured engine oil Systems are not correctly primed prior to initial engine start-up, after being installed in the vehicle. This may cause oil starvation during initial engine start-up.
Some vehicles equipped with the T45 transmission may exhibit a condition of being stuck in reverse, difficult to shift into reverse or may pop out of reverse. This may be caused by the 5th/Reverse Gear Shift Fork. This article does not apply to the condition of "unable to get into reverse" or "reverse block out".
This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants.
Ignition Switch - High Turning Effort/MIL ON/DTC's Set
Some vehicles may exhibit vacuum or air leaks in the Intake Manifold and/or Engine System causing DTC's, P0171 (System Too Lean (BANK 1), and/or P0174 (System Too Lean (BANK 11). This article can also be used if you suspect a vacuum leak that has not generated a DTC.
The hood scoop may come loose causing the hood scoop to detach from hood on some vehicles. This may be caused by loose attaching fasteners on the hood.
Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most 2-1 downshifts. This may be caused by a Planet Support Spring that is out of position.
A wire harness terminal repair kit is available for repairing electrical wiring harnesses. This kit allows the dealer to repair broken or corroded terminals instead of replacing an entire wiring harness.
A "whining" noise may be heard from the rear on some vehicles during coastdown from 97 to 56 km/h (60 to 35 mph). This noise will disappear when the vehicle slows down below 56 km/h (35 mph). This may be caused by variation in tooth contact between the differential ring gear, pinion, and by the inability of the original upper control arm bushings to isolate the noise.
Emissions/Engine Controls - Driveability Diagnosis
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
PATS System - Diagnostic Service Tips
Some vehicles may exhibit a hesitation and in some cases engine backfiring through the induction system on cold starts (27°C/80°F and colder) with no diagnostic trouble codes (DTC) present. The hesitation is exhibited on a low speed, high load condition. This may be caused by the calibration of the Powertrain Control Module (PCM).
Some vehicles may exhibit a vibration that may be heard or felt at the clutch pedal between idle and 2300 rpm, and goes away when depressing the clutch at least 25 mm (1"). This may be caused by the lack of reserve, quadrant binding, improper clutch cable routing, lack of preload on the release lever, improper or failed release bearing, improper pressure plate-to-flywheel bolt torque, or out-of-parallel finger height on pressure plate.
Contamination from prior transmission concerns or excess wear may be trapped in the transmission fluid cooling system. This debris must be removed by properly cleaning the transmission cooling system. After cleaning, some contamination may still remain. The remaining contamination may be reintroduced into the fluid cooling system of a repaired/replaced transmission causing premature or repeat failures.
Sport utility vehicles with steel hoods and certain pickup trucks equipped with sheet molding compound hoods. A wire formed hood striker could be susceptible to fatigue fractures. If the hood striker fractures, the hood could fly open while the vehicle is being driven.
Some vehicles may exhibit a hood that is hard to close. This may be cause by a hood latch support bracket that is improperly adjusted.
Recall - Park Brake Control Modification
The intake manifold may leak or weep coolant from passenger side gasket at right rear corner of head-to-manifold joint.
Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement.
The front windshield wipers may operate while the multifunction switch is in the OFF position on some vehicles. This may be caused by a resistance drift in the multifunction switch or a partially plugged-in connector.
Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting.
Customers may perceive that vehicle fuel economy is lower than it should be, based upon Environmental Protection Agency (EPA) estimates. Fuel economy is most influenced by vehicle usage and duty cycle.
The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected.
EVAP - DTC's P0442/P0455/MIL ON/No Driveability Concerns
A "popping" or "oil canning" noise may be coming from the driver's footwell area, approximately 152-203 mm (6-8") rearward of where the driver's heel would rest when operating the accelerator pedal.
The convertible top boot may fit improperly or be difficult to install on some vehicles due to the top not folding down all the way into the well.
A "creaking" noise from the LH rear quarter area when going over bumps may be heard on some vehicles. This may be due to contact between the inner rocker panel and the outer wheelhouse of the LH rear quarter area.
Recall 99V250000: Seat Belt Retractor Defect
Not all safety belt retractors require inspection. The safety belt retractors that will require inspection vary depending on the vehicle model. Refer to the "Safety Belt Inspection Chart" to determine which safety belt retractors are affected for the vehicle you are servicing.
Intermittent Transmission Control Indicator Lamp (TCIL) or Malfunction Indicator Lamp (MIL) illumination may occur on some vehicles. The following Diagnostic Trouble Codes (DTCs) may be stored in memory: P0741, P0750, P0755, and P1746. This may be caused by the solenoid interconnect molded lead frame not being fully seated or the bulkhead interconnect clips not being fully seated between the solenoid interconnect molded lead frame and bulkhead interconnect.
A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants.
This TSB serves as a guideline for servicing and diagnosing brake vibration, brake inspection, and brake friction material replacement.
A perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on some vehicles. The Powertrain Control Module (PCM) strategy is designed to delay shifts in some vehicles when Transmission Fluid Temperature (TFT) is below approximately 21°C (70°F) for taster heater warmup. The 2-3 shift may be delayed approximately 14-24 km/h (9-15 mph) when compared to the shift speed charts listed in the appropriate Service or Workshop Manual. A leaking 2-3 accumulator may cause Diagnostic Trouble Code (DTC) P0782.
Recall - Transmission Harness Rerouting
Some customers may have concerns that beverages will spill when put into the cup holder. This may be caused by the cup holder not being deep elough to fit large cups.
A new flush and fill tool has been released. This improved design simplifies fluid exchange within the vehicle.
Calibration information was not readily provided on some vehicles.
Comprehensive Noise/Vibration/Harshness Procedure
Paint - Rough Texture
Excessive road noise may be heard from the rear wheel area on some vehicles. Other potential concerns may be dust intrusion into the luggage compartment and/or evidence of a water leak in the luggage compartment. This may be caused by no material being on the wheelhouse flange located on the inside of the wheel well.
There has been an increase in the number of door trim panel replacements due to damage. This may be caused by a misconception of the type of fastener used to secure the door trim panel.
Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year.
Recall 99V062000: Sticking Cruise Control Cable
Some vehicles equipped with an automatic transmission/transaxle are being overfilled with transmission fluid after repairs and during the pre-delivery inspection. Over-filling the transmission/transaxle with transmission fluid may cause transmission shift concerns and/or internal transmission/transaxle damage. The 1999 Pre-Delivery Inspection (PDI) Manual is being revised for clarity.
The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM.
The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield.
Some vehicles using winter blend fuels may exhibit a stall on start up and a no restart, hard start condition or a no start condition in unseasonably hot weather (greater than 27°C/80°F). These concerns may be related to fuel volatility from winter blend fuels during winter-spring and autumn-winter transitions and may result in a fuel pump vapor lock condition. This condition may appear to be a fuel pump failure but may be caused by winter blend fuel.
Some vinyl covered items such as dash panels, door trim panels, consoles, etc., may exhibit a small (less than 5 mm deep) dent, scuff, abrasion and/or discoloration resulting from assembly, transit, dealer prep and/or customer usage. Replacement of these items is not necessary, except for air bag modules which must be replaced.
Ford Motor Company has released a new Electrical Grease (F8AZ-19G208-AA) to reduce the possibility of moisture corrosion at the terminals.
This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory.