TSB's and Special Messages
Some 2001 Mustang Bullitt may exhibit a hesitation or stumble over bumps
This condition may be followed by the theft light flashing for
a period of time, and diagnostic trouble codes (dtc's) C1284, U1147, U1262
may also be present. When diagnosing you may find no communication with
the PCM. This condition may be caused by the DPFE wiring chaffing against the
DPFE bracket shorting out VREF. Repair the wiring and re-route the DPFE
wiring to run over the accelerator cable to prevent this condition from
Coolant fill procedure
At times in order to completely remove any trapped air in the cooling system of vehicles equipped with 4.6/5.4/6.8L Modular engines, it is necessary to use the following procedure: Disconnect the heater hose at the right front or rear of the engine, remove the thermostat and housing using the thermostat opening carefully fill the engine with the proper clean coolant mixture until observed at the engine side heater hose connection. Reconnect the heater hose and reinstall the thermostat and housing. Fill the degas bottle to the coolant fill level mark run the engine until it reaches normal operating temperatures select max heat and max blower speed on the climate system if the heat output is insufficient, or the engine does not reach normal operating temperatures, verify proper thermostat operation and repeat procedure if required.
4.6L 4V Pulley Instructions
Some 1996-2001 Mustang owners, for engine performance purposes, are adding a special front drive pulley kit to reduce front accessory drive speeds. When removing and replacing the crank pulley, if the large bolt used to hold the crank pulley undertorqued, the keyway will shear and cause major engine damage. The resulting engine damage is not warrantable. If the crankshaft pulley bolt is removed it should be replaced as it is a torque to yield bolt. The installation of the crankshaft pulley requires that a specific torque operation be adhered to. The crankshaft pulley bolt must be installed using these 4 steps: 1) Torque to 75 lbs/ft 2) Back out one turn 3) torque to 45 lb?ft 4) continue to tighten and additional 90 degrees.
Vapor Management Valve Noise
Some 1996-2001 Mustangs may exhibit a high frequency air leak/rushing sound from the underhood/dash area. This may be caused by the vapor management valve mechanically grounding to an unseated stud mounting clip. To service, remove the vapor management valve. Reseat the stud mounting clips to the front right inner fender apron, and remount the vapor management valve without unseating the stud clips.
CHECK G103 - MULTIPLE ELECTRICAL SYMPTOMS
SOME 1999-2001 MUSTANGS MAY EXHIBIT ONE OR MORE OF THE FOLLOWING SYMPTOMS: HARD START, DIAGNOSTIC TROUBLE CODE (DTC) P1233 AND/OR P1414, RIGHT FRONT EXTERIOR LIGHTING, TURN LAMP ERRATIC AND ANTI-LOCK BRAKE (ABS) WARNING LAMP ON. THIS MAY BE CAUSED BY A LOOSE G103 ATTACHMENT. G103 IS LOCATED ON THE RIGHT FRONT RADIATOR CORE SUPPORT/INNER FENDER AREA. REFER TO EVTM 10-3 FOR ADDITIONAL INFORMATION.
Torque Specification for oil pressure sensor
Whenever the oil pressure sensor/sending(9278) is removed and installed or replaced on a vehicle equipped with a 4.6/5.4/6.8L engine, it is important that the sensor be torqued to 12-16 NM. Over-torquing of the sensor can lead to an oil leak and/or damage to the oil filter adaptor.
R&R oil pressure switch F8AZ-9278-DA with 1U5Z-9278-DA
Some 1999-2001 Range, Explorer/Mountaineer, Crown Victoria/Grand Marquis Town car, Mustang, F-150, Super_duty F-series, F650/750, Expedition/Navigator, E-series and Excursion may exhibit the oil pressure gauge registering low or no oil pressure usually on initial start-up after several hours of cold soak. Verify the gauge/wiring are functioning properly and verify the engine does have proper oil pressure To service replace existing oil pressure switch F8AZ-9278-DA with 1U5Z-9278-DA. If any engine oil was lost during removal and installation refill to t appropriate oil level requirements reference your appropriate workshop manual for complete service procedure.
Clutch cycle noise
Some 1994-2001 Mustang equipped with a manual transmission may have a powertrain noise described as a brief roar, hoot, or groan between 2500-3500 RPM when the clutch pedal is half way down, during shifting or when depressing and releasing the clutch. This condition is characteristic of a mecahanical clutch cable release system and does not indicate any system mechanical or durability issues, no attempts to service this condition should be made.
2001 Mustang - T-3650 Transmission shift fork bending
Some 2001 V-8 Mustangs equipped with TR-3650 transmissions built from Feb-2001 to Aug 2001 may exhibit difficulty engaging 1st or 2nd gear. This may be due to an out-of-spec 1-2 shift fork. A new shift fork has been developed to service this condition (2r3z-7230-aa). Remove transmission and follow service procedures detailed in 308-03c for dissassembly and assembly of replacement 1-2 shift fork. Examine 1-2 syncronizer and blocking rings for any damage. Service as necessary following service procedures in 308-03c.
AUTHENTICITY STICKER DAMAGE
SOME 2001 BULLITT MUSTANG MAY HAVE THE LETTERING COME OFF THE BULLITT AUTHENTICITY STICKER THAT IS FOUND ON THE DRIVER'S SIDE SHOCK TOWER. THIS MAY BE DUE TO THE USE OF CERTAIN CLEANING PRODUCTS. IF THIS DOES OCCUR OR THE STICKER IS DAMAGED IN ANY WAY, PLEASE CONTACT OUR SPECIAL SERVICE SUPPORT CENTER AT 1-800-325-5621 TO OBTAIN ONE (1) REPLACEMENT STICKER. THIS STICKER WILL NOT BE RELEASED FOR SERVICE AT A LATER DATE. THEREFORE, THIS WILL BE THE
ONLY STICKER PROVIDED. DEALER WILL NEED TO PROVIDE THE VEHICLE IDENTIFICATION NUMBER (VIN), BULLITT STICKER # AND REFERENCE THIS SSM # AT THIS TIME. THIS SERVICE CENTER CAN BE CONTACTED M-F 7:30AM-7:30PM EASTERN STANDARD TIME (EST) AND SAT. 8:00AM-5:00PM .
Mustang-TR3650 cold gear clash - change fluid
Some 2001-2002 V-8 Mustang with a a TR3650 Manual Transmission built prior to March 15, 2002 may exhibit a clash/grinding sound during the first few miles of driving. To reduce this condition, completely drain the transmission fluid and fill full with 128 oz. (4 qts.) of Motorcraft Mercon ATF, using ford part # XT-2-QDX. Note: AT full fill, the fluid may not reach the bottom of the fill hole. Do not over fill. Note: the full benefit of the fluid may not be realized (for the concern of clash/grind) until the new oil has been driven for several hundred miles.
A Mechanical Noise (Buzz, Growl, Scraping, Zip) May be heard on drive away after initial start-up.
Some 1992-2002 vehicles equipped with anti-lock brakes may exhibit a mechanical noise (Buzz/Growl) on drive away after initial start-up. Each time the vehicle is driven. As vehicle speed reaches approximately 11-32 KM/H (7-20 MPH). The anti-lock brake control module turns on the pump motor and valves for approximately one half second. At this time a mechanical noise (Buzz, Growl, Scraping, Zip) maybe heard. This is a normal function of the self-check by the anti-lock brake control module for additional information refer to workshop manual section 206-09.
Mustang 4.6L 2V cold start rattle
Some 2001-2002 Mustang GT equipped with a 4.6L 2V engine and a manual transmission, may exhibit a cold start piston rattle. Engineering is investigating this condition using the quicker service fix (QSF) process. Do not attempt any service at this time. Continue to contact the national hotline to verify condition. A service fix should become available in the second quarter submit EDSR's and continue to monitor oasis for updated information.
Do not repair spark plug port threads in aluminum cylinder heads- Unapproved usage of helicoil for service
Some engines equipped with aluminum cylinder heads may exhibit spark plug port(s) with stripped or missing threads, "Do not" service stripped or missing spark plug port threads by using "helicoil" or "tapersert" repair kits. It is likely that additional engine damage or engine failure will occur after an unsuccessful attempt to service the cylinder head spark plug reports with "helicoil" or taperset. The only authorized service procedure is to replace the cylinder the cylinder head assembly when spark plug port threads are damaged is to replace the cylinder head assembly when spark plug port threads are damaged and in need of service, refer, to the pertinent workshop manual (section 303-1) for cylinder head removal and installation procedures. Note: When servicing spark plugs for any reason , do not use air or power tools and take care to ensure that spark plugs to not cross thread.
3116 Can someone verify this number and also is it a message or a bulletin?
Mustang - Cold engine light ticking/rattle noise:
Some 2001-2002 Mustang GT and Bullitt with the TR3650 Manual Transmission may exhibit a light ticking/rattle noise while driving after a cold engine start. The noise will typically occur between 2200-3500 RPM under light throttle (1/8 to 1/4 open) while driving. The noise may last for a few minutes (depending on temperature). The condition is due to the combination of light load operation noted above and normal piston to cylinder bore clearance present in the cold engine. To service, verify condition & reprogram the PCM with the latest calibration available via the just-in-time process if your WDS communicates with Fordstar. Also obtain calibrations on the Ford Professional Technician Society (PTS) website - select WDS then PCM reprogramming and click instructions for downloading...
TECHNICAL SERVICE BULLETINS
Transmission - fluid in -line filter kit - repeat repairs of transmission - service tips: after every overhaul or transmission exchange, clean, flush and back flush the transmission fluid cooling system. Refer to the TSB service procedure for details.
Vibration, clutch-vibration heard and/or felt at clutch pedal: This may be caused by 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. Refer to TSB
Fluid - Transmission Fluid usage charts: for proper fluid application on current and past vehicles equipped with manual or automatic transmission or transaxle refer to the fluid usage chart (Figures 1,2 and 3)
Driveability - Diagnostic trouble codes (DTC) P0171 and/or P0174 - Detecting vacuum leaks - Using the Rotunda Vacutec 522 smoke leak detector machine: refer to the TSB for details
Driveability - Electrical sticking or binding ignition lock cylinder high effort when turning ignition switch diagnostic trouble codes (DTC) P0500, P1502 and/or U1039 on some vehicles: Replace the key-in-ignition warning chime switch located on the ignition switch lock cylinder refer to the TSB.
Engine - Engine oil system priming procedures - service tips: Prior to starting a new, overhauled or remanufactured engine, the oil pump and oil system should be primed to eliminate the possibility of oil starvation at start-up. Refer to the TSB for details.
Engine - Approved head gasket replacement service procedures: Refer to the TSB for recommended gasket sealing surface preparation procedures.
Engine - Engine oil - Recommended applications for SAE 5W-20 and SAE 5W-30 Motor oils - Gasoline and flexible fuel vehicles only: All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. Refer to the TSB for details.
Engine - Machining of aluminum cylinder heads or blocks Warranty information: Engineering has determined that the surface finish quality standard cannot be met to specification by field-sourced machine shop facilities. Cylinder head assemblies/short and longblock assemblies are available through your FAD.
Engine 4.6L Front end accessory drive (Feed) belt slips off water pump pulley when splashed with water: Verify condition. Replace the water pump pulley and/or tensioner assembly as necessary. Refer to the TSB for details.
Old water pump Pulley
New water pump Pulley
Some 2001-2003 model year Mustangs may exhibit
a whistle type wind noise form the "A" pillar area.
This may be caused by wind moving over the fastener holes of the "A" pillar applique
Verify condition by taping off the area. install a foam block in the applique to keep wind from
passing over the hold causing the whistle.
I know that this is not a Ford TSB or Special Message but it is from the manufacture of the transmission, Tremec, so I thought I would add it here.
NOTE:From Tremec dated 03/01
Service Bulletin 03.01
Aftermarket Shifter Stops
Transmission Models Affected:
Severe damage may be caused by installing an aftermarket shifter
with "shift stops" on any TREMEC transmission. All TREMEC
transmissions are designed and manufactured with built-in shift
stops to prevent over shifting. Therefore; shift stops on
aftermarket shifters are totally unnecessary when used on a
TREMEC transmission. TREMEC "TR series" transmissions have
multiple shift rails with shift stops on the gearing. TREMEC "T
series" transmissions have a single shift rail system with stops
built into the guide plate.
When installing an aftermarket shifter on a TREMEC transmission
it is best to remove the shift stops to avoid miss adjustment,
and the potential of the screws vibrating lose. A misadjusted
shift stop can cause an under-shift, which may lead to a gear
jump-out situation. If the transmission jumps out of gear, the
shift fork can be bent causing permanent damage to the
transmission. Shift forks can also be damaged by "clash
shifting". A clash is caused by a missed shift.
Neither an "under-shift", nor a "clash shift" can be prevented by shift stops. TREMEC shift forks are designed to take loads up to 1,000 lbs. However, a gear jump-out may well exceed 1,000 lbs. of force, which may result in a permanently damaged transmission.
Engine - 4.6L 2V-TICK NOISE FROM ENGINE-ENGINES BUILT BEFORE 8/29/2003
Some vehicles, equipped with the 4.6L 2V engine,
with an "ENGINE BUILD DATE" prior to 8/29/03 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 not e heard with the hood open.
TR3650 MANUAL TRANSMISSION-JUMPS OUT OF GEAR 2ND AND/OR 3RD-CLASH NOISE AND/OR
RASPY FEEL ON GEAR ENGAGEMENT
Some 2001-2003 Mustang vehicles, equipped with TR3650 5 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 (5C).