The below Technical Service Bulletins, TSB for short, were issued for the 2001 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.
Body - Exterior Mirror Damage Warranty Information
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.
A/T - Transmission Cooler Flush Information
Various vehicles equipped with a 3.8L, 3.9L or 4.2L engine and Split Port IMRC may exhibit spark knock under light load and acceleration.
Battery - Battery Eye Function/Charging/Service
Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area.
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.
Cruise Control - Diagnostic Updates
Approximately 50% of coil on plug (COP) coils returned for warranty do not have a problem.
Electrical - Wiring Soldering/Crimping Service Tips
To service a safety belt web stop button (the button that keeps the belt tongue from sliding down when not in use), a service kit is now available.
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 LX vehicles, equipped with a 3.8L or 3.9L engine may exhibit an exhaust leak. This may be due to a cracked or fractured right side exhaust pipe, just forward of the first catalytic converter. This crack may be due to condensation dripping onto the pipe.
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).
This article is intended to aid in diagnosing DTC's P0171, P0174, P1130, P1131, P1150, P1151, P2195, or P2197 (system lean or lack of HEGO switches) when a vacuum leak is present. HEGO sensors, MAF sensors, and PCM replacements are not an effective repair when a vacuum leak is causing the above DTC's.
Recall - Tube Mounted EGR Pressure Sensor Defect
Some 2001-2003 Mustang vehicles, equipped with TR36505 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).
Some vehicles may exhibit inoperative electric rear window defroster (heated backlite) grid lines, integral antenna concerns causing radio reception issues or terminal tabs pulled from the rear window glass.
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
Some 2001-2004 Mustang vehicles may exhibit climate control panel vents (barrel vent) with vanes that are difficult to adjust, and/or may make a rattling type noise. This may be due to detachment of the air vanes from the pilot holes in the vent housing.
Some 2001-2003 Mustang Coupes may exhibit the headliner sagging in the rear of the vehicle.
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.
Some vehicles may exhibit a group of small pin head sized holes in the paint film or delamination on the vehicle's hood.
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 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.
Engine Controls - DTC P1635 Set After PCM/IC Replacement
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.
Some 2001-2003 model year Mustangs may exhibit a whistle type windnoise from the "A" pillar area. This may be caused by wind moving over the fastener holes of the "A" pillar applique.
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.
Some Mustang convertible vehicles may exhibit difficulty in securing the convertible top boot (cover), which may result in a poor fit. This may be caused by the snaps not holding the boot securely in place.
On some vehicles equipped with the 4.6L engine, the Front End Accessory Drive (FEAD) belt may hydroplane on the Water Pump pulley when the belt is splashed with water. This may cause the belt to track forward on the tensioner pulley. The belt may then slip off the tensioner pulley.
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 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.
Campaign - IMRC Set Screw Inspection/Repair
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
PATS System - Diagnostic Service Tips
Some vehicles equipped with the 4R70W automatic transmission may exhibit a "Ticking" or "clicking" type noise in first gear. This may be caused by the intermediate clutch moving inside the transmission.
Some 2001 Model Year 3.8L Mustang engines may have oil pumps built with a new sealing process called Liquid Injection Sealing (LIS). An LIS service procedure is not yet available to the field.
Some vehicles equipped with a 3.8L engine may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Code (DTC) P0442. Vehicles equipped with a 4R70W automatic transmission may also exhibit a slip/bump on the 1-2 shift or a harsh 2-3 shift at hot operational temperatures. This may be caused by the calibration of the Powertrain Control Module (PCM).
The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning function. This feature provides additional reminders to the driver that the driver's safety belt is unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the instrument cluster.
Warranty - Guide Supplement
Some 2000 Model Year 3.8L Mustang engines may have oil pumps built with a new sealing process called Liquid Injection Sealing (LIS). An LIS service procedure is not yet available to the field.
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.
Recall 00V349000: Hood Striker Fracture/Failure
Recall - Park Brake Control Modification
A/T - 'Prior To Repair' Tag Procedure Notice