The below Technical Service Bulletins, TSB for short, were issued for the 2005 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.
Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs.
Some Mustangs may exhibit inoperative electric rear window defroster grid lines or terminal tabs pulled from rear window glass.
This Weld Bonding Procedure should be used on all Ford Mustangs when replacement of any OEM weld bonding component (structural and nonstructural) becomes necessary, unless specifically directed otherwise by a Ford Technical Publication specific to a particular vehicle.
Some 2005 Mustang vehicles equipped with a 4.6L 3-valve engine, may exhibit the MIL (malfunction indicator lamp) illuminated with multiple ignition coil related DTCs (diagnostic trouble codes) and no drive-ability symptoms. The DTCs are typically set during deceleration and begin with P035X, with X being and number 1 thru 8.
When diagnosing for a possible MAF (mass air flow) sensor related condition, on a vehicle equipped with an EGR (exhaust gas recirculation)system module (ESM), an incorrect engine-running BARO (barometric pressure) value is no longer a reliable indicator of a skewed MAF sensor. Vehicles with ESM use both the MAP (manifold absolute pressure) and MAF for engine-running BARO updates. Replacing the MAF sensor for a seemingly incorrect or inconsistent key-on BARO is not an effective repair for vehicles equipped with an ESM.
Some 2005 Mustang vehicles built before 10/02/2004 may exhibit the air bag warning lamb on with diagnostic trouble code (DTC) B1891 or the lamp flashes code 53 (Air Bag Tone Warning Indicator Shorted To Voltage). The restraint system remains fully functional.
Some 2005 Mustang vehicles equipped with a 4.0L V6 engine and automatic transmission may exhibit an exhaust vibration or resonance at approximately 850 RPM.
Ford Motor Company has adopted a new premium interior paint formulation that has significantly improved performance properties. When used as directed, the product preserves the original grain pattern of the plastic, is UV stable color fast, and is completely flexible. It will not crack, flake, or peel. Motorcraft Spray Paint, PM-19M547-XXXH (XXXX = Color Code), can be used for both paint-to-match and repair procedures.
The convertible top latching mechanism on the 2005 Mustang is significantly different than prior model years. Vehicle owners may have difficulty in latching the top if they are not aware of the unique operating characteristics of the new latch design.
Some 2005 Mustang vehicles built before 02/24/2005, and equipped with a 6 disc CD player with MP3 capability (e.g. radio must have MP3 logo present), may exhibit one or more of the following intermittent CD player concerns.
Some Mustang vehicles built 11/29/2004 and prior may exhibit the wrench light on with both P2106 and P2135 diagnostic trouble codes (DTCs)
Some 2005 Mustang vehicles equipped with the 4.6L 3V V8 engine and the TR3650 manual transmission built before 02/21/2005 may exhibit an intermittent raspy grinding noise while driving in 2nd and/or 3rd gear during acceleration. The noise may sound like a bearing growl, screech, or scraping noise. Noise intensity may be light to medium, and is more likely to occur during the first few minutes of warm-up.
Some 2005 Mustang vehicles built before 04/26/2005 may exhibit the fuel tank being slow or difficult to fill. The condition may be described as repeated rapid shut-offs of the filling station pump nozzle, or multiple nozzle shut-offs when attempting to fill the fuel tank. The condition may be due to the fuel tank vapor venting system inside the fuel tank.<
Some 2005 Mustang vehicles may exhibit a concern with the front side marker lamp retainer tab breaking in the front bumper cover, due to an impact.
Mustang wire harness repairs are supported through the availability of individual components listed in this bulletin.
Some 2005 Mustang vehicles built before 03/08/2005 may exhibit occasional brake noise during light to moderate decelerations from speeds below 40 MPH (64Km/h), often described as a high-pitched squeal or screech.
Some 2005 Mustangs built before 05/10/2005 may exhibit the seat cushion cover front trim being loose on the front seat. The J-clip that holds the seat cushion cover trim to the front of the seat pan (frame) may not be fully engaging the flanges (slots) in the seat frame (pan).
Approximately 50% of coil-on-plug (COP) coils returned for warranty do not have a problem.
Some 2005-2006 Mustangs with an FS-10 A/C compressor may experience a non operational air conditioning compressor due to a low freon level caused by a leaking shaft seal.
Some 2005-2006 Mustangs built prior to 10/01/2005 may exhibit park brake cables that freeze in cold weather due to water intrusion, and subsequently not release. Under some conditions this could lead to dragging rear brakes. The rear sealing boot on the cable could deteriorate prematurely which may permit water intrusion. In freezing temperatures this could bind the cable inside the casing, and not allow tension to be released from the caliper.
Some 2005-2006 Mustang GT vehicles may exhibit the malfunction indicator lamp (MIL) on, with diagnostic trouble codes (DTCs) P2004 through P2008, P151A, P2015, and P2020. All of these codes are associated with the charge motion control valve (CMCV), actuator motor, and/or linkage concerns.
Some 2005-2006 Mustangs may exhibit a hesitation on acceleration after a long cruise. After coming to a stop from a highway type cruise, some vehicles may experience a hesitation when the customer begins to accelerate. Air bubbles can form around the fuel pump during a long cruise and can be ingested into the pump on acceleration causing a hesitation.
Some 2005-2006 Mustangs equipped with a 4.6L engine may experience a failure of the air conditioner (A/C) compressor clutch assembly. A revised design A/C compressor clutch is available for service. Installation of the revised design clutch also requires installation of a new orifice tube and a reduced refrigerant charge.
Some Mustang 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.
Ford Motor Company has “consolidated” high and low content harnesses to make the service selection easier, and to reduce the number of harnesses required for service. Due to this consolidation, service replacement harnesses may or may not look exactly like the production harness being replaced. Service replacement harnesses may come equipped with additional connectors that will not be used.
When servicing the head gasket on certain Ford remanufactured engines in 2005-2006 Mustangs, it is critical to determine the type of remanufactured engine that is being serviced, in order to identify the correct replacement gasket.
Some 2005 Mustang vehicles equipped with the 4.6L 3V engine may exhibit a ticking and/or knocking noise after reaching operating temperature, or a rattle upon starting. The noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a normal characteristic of these engines. In other cases the noise may require further investigation. Sorting out and defining the noise as reported by the customer is important to successfully diagnose and/or repair the condition.
Some 2005-2006 Mustang GTs may exhibit a diagnostic trouble code (DTC) P0340 and/or P0349. This may be due to a malfunctioning diode or open phase connection in the generator/alternator.
Some vehicles may require the audio or navigation unit to be replaced. A new Service Procedure is available for 2005-2007 Mustangs.
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.
Some Mustangs may exhibit a bubbling or blistering under the paint on aluminum body parts. This is due to iron contamination of the aluminum panel.
MERCON® automatic transmission fluid is being replaced by MERCON® V as the service fluid for manual transmissions originally requiring MERCON®.
Some 2005-2007 Mustang vehicles may need to have the carpet replaced for various issues. The following procedure will allow the carpet to be removed and replaced without removing the heater/air conditioning plenum, instrument panel, or restraints control module (RCM).
MERCON® Automatic Transmission Fluid is being replaced by MERCON® V as a service fluid for power steering systems originally requiring MERCON®.
Some 2005-2006 Mustangs may have a malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0456. This concern can be caused by an oversized orifice in the fuel pump. Suspect fuel pumps are in vehicles built before January 1, 2006.
Some Mustangs equipped with leather-wrapped steering wheels may exhibit the leather coming loose from the spoke area.
This TSB describes the operation and function of the Battery Eye and correct battery recharging procedures.
Some 2005-2008 Mustang vehicles may experience a no start and have a discharged battery. They are usually stored for prolonged periods of time or are driven infrequently for short distances. Batteries will discharge while the vehicle is in storage due to normal current draw loads. Over a period of time, 30 days or more, vehicles in storage will have shallow to deeply discharged batteries as a result of lack of use or normal current draw.
2005-2007 Mustangs are equipped with a restraints control module (RCM) that reports diagnostic trouble codes (DTCs) which provide general fault information. These DTCs require accessing the associated bit-mapped PIDs to identify the specific fault. Most Workshop Manuals were written using New Generation STAR Tester (NGS) terminology and navigation which does not translate well when using Integrated Diagnostic System (IDS), Portable Diagnostic Software (PDS), or Worldwide Diagnostic System (WDS).
Some 2005-2008 Mustang vehicles may exhibit an exterior door handle not flush in the closed position. This may result in a loose handle, rattle noise, hard to open, and/or door self locks when opening outside handle.
Some 2005-2008 Mustang vehicles built before 8/2/2007 may experience a buzz/rattle from the door panels when using the radio/CD player at elevated volumes or bass levels or voice broadcasts. This may be due to the window switch bezel vibrating against the door trim panel. This can often be incorrectly diagnosed as an audio speaker buzz or a bad speaker.
Some 2005-2008 Mustang convertible vehicles may require a repair of the convertible top. Individual components should continue to be used where appropriate, but if required a new top assembly is now available.
Some 2005 Mustang vehicles built before 4/8/2005 may exhibit an intermittent popping noise from the front of the vehicle while turning left or right. The noise will typically occur during low speed maneuvers and may occur multiple times while turning.
Some 2005-2007 Mustang coupes equipped with 4.0L or 4.6L (excludes GT500 and convertibles) may exhibit a "loose lumber", rattle, or chuckle sound from the front end over bumps and rough roads.
Some 2005-2007 Mustang vehicles built before 10/11/2006 and equipped with a convertible top could develop wear or a hole near the 4th bow and/or number 1 bow area. This is caused by the number 1 and number 4 bow wearing oe pinching through the vinyl or cloth top.
Some 2005-2007 Mustang Convertibles built before 12/01/2006 may exhibit a tick, pop, rattle, snap, creak type noise that sounds like it originates above the front door glass area and/or convertible latches. The concern is caused by a stick/slip condition between the cable and the top. The cable runs from the number 1 bow to the number 5 bow and maintains the shape of the window opening. The noise resonates through the cable to the number 1 bow.
Some 2005-2007 Mustangs may experience premature shut off of the fuel fill nozzle. Several variables, including variations in fuel pump nozzles, fuel flow rates, and fuel flow pressure may result in the premature automatic shut off of the fuel fill nozzle making it more difficult to fill the fuel tank. The automatic shut off in the fuel fill nozzle may trigger multiple times after delivering several gallons of fuel or it may trigger repeatedly when attempting to establish fuel flow into the tank. The latter concern may be more common when adding fuel to a vehicle where the fuel level is at or above 1/2 full.
Some 2005-2008 manual transmission equipped Mustangs (excluding GT500), and built before 12/06/2007, may exhibit a tick noise from the shifter boot in forward gears 1st, 3rd, and 5th.
Some 2005-2008 Mustang vehicles built before 12/03/2007 may exhibit a concern with a rattle, buzz, or vibration from either the center stack console (radio/heater area), steering wheel, seat, floorpan, and/or gearshift area.
Some 2005-2006 Mustangs may have an erratic fuel gauge concern (does not read full or reads empty when tank is full). This may be caused by poor electrical connections at the fuel sender, at the in line harness connector, and/or faulty fuel sender card.
Some 2005-2007 Mustang GTs equipped with the 8.8 inch limited slip axle may exhibit a moan/groan noise when making tight low speed turns. This may be more noticeable when the axle is at full operating temperature. The noise may also be confused as originating from the brakes or steering system.
Some 2005-2008 Mustangs with the 4.6L 3V engine may experience difficulty with spark plug removal. This may cause damage tot he spark plug and leave part of the spark plug in the cylinder head. Affected engine dates are before 11/30/2007.
Some 4.0L manual transmission 2005-2007 Mustangs may exhibit a rattle or knocking noise on light acceleration between 1800-2200 RPM around 45 MPH (72 Km/h). It is most evident in 4th gear after the engine/transmission has reached operating temperatures. It has been described as a helicopter noise, similar to when you put a playing card in bicycle spokes. The noise has no affect on vehicle performance or durability.
Some 2005-2009 Mustang convertible vehicles may exhibit a torn / separating quarter glass division bar due to misalignment between the front door window glass and the rear quarter window glass. Concern may be duplicated with convertible top down, quarter glass down and front door glass up. When the rear glass is raised, it may catch on the front door glass creating a scissor effect over time. The windows need to be aligned to each other and the convertible top, as a glass system.
Some 4.0L manual transmission 2005-2006 Mustangs may exhibit the RPM fluctuating up and down (also called surging) while coasting in neutral with clutch pedal released. No diagnostic trouble codes (DTCs) will be present. The RPM will drop back to idle with clutch pedal depressed.
Some 2005-2009 Mustangs may exhibit issues with the power window one-touch up, bounce back, and short drop features.
Some 2005-2009 Mustangs (excludes GT500) equipped with either a 4.0L or 4.6L engine may exhibit a heavy driveline shudder on acceleration from a stop or between 3-15 MPH (5-24 Km/h). On 4.0L engines there may also be an above average engine presence. The wrong transmission crossmember assembly may have been installed from the factory. Similar complaints may also occur if the transmission crossmember and transmission support insulator were improperly reassembled after transmission removal.
Some 2005-2009 Mustang vehicles may exhibit a rattle noise where the A-pillar meets the dash area. This rattle may be due to worn, missing or off location tape under the dash panel and/or A-pillar dual lock (velcro) fastener(s) not seated.
Some 2005-2009 Mustang vehicles may exhibit a difficult to diagnose water leak in the front floor area. This may be caused by loose grommets and/or sealer skips around the cowl area, loose A-pillar window weatherstrip retainer, misaligned body harness grommet through the firewall, misaligned body harness grommet from the passenger door.
Some 2005-2009 Mustangs equipped with a 5R55S automatic transmission may experience shifting concerns. A loss of 2nd, 3rd, and 5th gear may have overdrive band or intermediate band failures due to servo pin case bore wear causing reduced apply pressure.
Some 2005-2010 Mustang vehicles built before 04/05/2009 and equipped with a 4.6L engine and manual transmission, may exhibit an oil-canning or exhaust rattle/buzz around 2000 - 2500 RPM during the first few minutes of driving after a cold start. The sound goes away after the car warms up. The concern may be caused by the separator plate, between the rear face of the engine block and the transmission housing, vibrating and/or contacting the flywheel.
Some 2005-2010 Mustang vehicles may exhibit excessive axle whine noise.
Some 2005-2010 Mustang 4.0L/4.6L, 2007-2010 Mustang Shelby GT500 vehicles built on or before 8/3/2009 may exhibit a grunt/creak/squeak/chirp noise from the lower control arm hydro bushing. The grunt/creak noise may occur over large vertical bumps like speed bumps and pot holes. The squeak/chirp noise may occur over bumps rough roads, and driveway approaches.
Some 2005-2010 Mustang vehicles equipped with a convertible top may exhibit a headliner that pulls away from the number 1 bow.
Some 2005-2010 Mustangs equipped with a 4.0L engine may exhibit a buzz noise from the upper engine at about 1900 RPM under light load acceleration.
Some 2005-2011 Mustang vehicles with the axle vent on the right (passenger) side may exhibit a heavy fluid leak from the rear axle vent after hard acceleration.
Some vehicles may exhibit diagnostic trouble codes (DTCs) P0505, P0506 and/or engine idle RPM fluctuation and hard starts. These vehicles may also exhibit DTCs P2111 and P2112 after KAM has been is cleared, or the battery has been disconnected or the vehicle had a dead battery. On vehicles with over 10,000 miles the issue may be caused by sludge buildup in the electronic throttle body (ETB) leading to airflow being less than desired.
2005-2006 Mustangs may exhibit Diagnostic Trouble Codes (DTC) P0505, P0506 and/or engine idle RPM fluctuation and hard starts. Some vehicles may also exhibit DTCs P2111 and P2112 after a keep alive memory (KAM) clear, battery disconnect or dead battery. On vehicles with over 10,000 miles, the issue may be caused by sludge buildup in the throttle body leading to less than desired airflow.
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