The below Technical Service Bulletins, TSB for short, were issued for the 2002 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
Body - Paint Defects Warranty Information
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.
This TSB describes the operation and function of the Battery Eye and correct Battery Recharging procedures.
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
Some 2003-2004 Expedition, 2003 Navigator, 2004 F-150 vehicles equipped with a 9.75" or 8.8" limited slip rear axle, and 2002-2004 Explorer 4dr, Mountaineer, 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.
Approximately 50% of coil on plug (COP) coils returned for warranty do not have a problem.
Electrical - Wiring Soldering/Crimping Service Tips
Some 2002-2004 Mustang vehicles may exhibit a squeak or creak type noise when turning.
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 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.
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 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, equipped with the Romeo built 4.6L 2V engine, with an "ENGINE BUILD DATE" prior to 9/17/2003 may exhibit an engine tick noise that is present at all temperatures during idle. The noise may be emanating from the valve guide area in the cylinder head. The noise may be more prevalent in the front wheel well area and may not be heard with the hood open.
Some vehicles may exhibit a group of small pin head sized holes in the paint film or delamination on the vehicle's hood.
Prior to replacing an. entire exterior mirror assembly, examine the mirror closely and determine if repairs can be made utilizing a service kit or other serviceable components such as mirror glass, mirror motors, bulbs, etc. Determine also whether the mirror's complaint condition may be the result of an impact or add-on accessory, as repairs for these reasons may not be covered under warranty. Diagnose the condition using the Workshop Manual. Refer to the following Service Procedure.
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.
Reports from the field indicate incorrect or low engine oil levels are being found at Pre-Delivery Inspection on new vehicles received in dealer inventory. In most cases, the level is being misinterpreted because the fluid fill mark on the stick is not touching the top hash mark at the upper limit (or MAX mark), or is partway down the crosshatch area.
This article is being written to clarify the proper procedures to prepare plastic fascia parts. Multiple repair procedures for painting plastic fascia parts are being used in the field that are inconsistent and may not provide adequate paint adhesion. Paint companies repair procedures are system specific and do not lend themselves to generic repair procedures.
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.
Engine Controls - DTC P1635 Set After PCM/IC Replacement
A new, extended-life engine coolant, yellow-colored Motorcraft Premium Gold Engine Coolant, meeting Ford Specification WSS-M97B51-A1, service part numbers VC-7-A and VC-7-C (for use in the U.S., except California and Oregon) and VC-7-B (for use only in California and Oregon as it contains a bittering agent), has been equipped in all of the vehicles noted above. The initial-fill life for this coolant is 100,000 miles/5 years. Due to variations in water quality, the replacement interval is 50,000 miles/3 years.
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.
Some vehicles equipped with a 4.6L 2V engine built before May 17, 2002, may exhibit an oil leak coming from the camshaft/valve cover area, where the positive crankcase ventilation (PCV) valve mounts. This leak may be caused by the stack up tolerance between the PCV valve and tube assembly.
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.
This procedure is being published to advise all body and paint technicians about proper procedures for preparation of service sheet metal parts coated with Electro Deposition Primer (E-Coat).
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.
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