The below Technical Service Bulletins, TSB for short, were issued for the 2003 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
Tire Monitor Sys - TPMS Identification
A/T - Transmission Cooler Flush 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 2002-2006 vehicles equipped with an FS-10 A/C compressor may experience a non operational A/C compressor due to a low freon level caused by a leaking shaft seal.
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
A service kit is now available to improve safety belt retraction speed.
Ford Motor Company's goal is to eliminate paint related repeat repairs and increase customer satisfaction. To meet this goal, Ford has tested ten major refinish paint suppliers materials for warranty repairs. Tests were conducted to paint material specification WSS-M2P100-D for refinish paint materials.
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 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 2003-2004 Mustang Cobra vehicles equipped with a Tremec T56 6 speed manual transmission, may exhibit a rattle noise or a difficult to shift condition. This may be due to a cracked or broken release bearing guide tube.
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 2003 Mustang vehicles with an automatic transmission may exhibit the following gear selector lever conditions:
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.
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 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.
2002 Taurus/Sable vehicles equipped with the 3.0L 2V built after 4/8/2002 and vehicles equipped with the 3.0L 4V Duratec built after 5/8/2002, 2003 Crown Victoria/Grand Marquis/Mercury Marauder and Lincoln Town Car equipped with 4.6L 2V/4V built after 09/15/2002, and 2003 Mustang equipped 3.8 & 4.6 2V/4V built after 09/15/02, will no longer have the Fuel Pressure Relief Valve (Schrader Valve).
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.
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.