Ford Mustang (1999-2004) Service Manual: Body System (Diagnosis and Testing)

Inspection and Verification

Leaks

NOTE: Trim will reveal the location of most leaks.

1. Remove any trim or carpet in the general area of the leak.

2. Road test or water test the vehicle.

3. Inspect for a dust pattern around the area in question. Inspect for water paths near and above the area in question.

4. Some leaks can be located by placing bright light under the vehicle, removing any necessary trim or carpet, and inspecting the interior of the body at joints and weld lines.

Noise

Wind noise, rattles, and their sources are detected by driving the vehicle at highway speeds. The vehicle should be driven in four different directions with all of the windows closed, the radio off, the blower motor off, and all of the ventilation ducts open.

Most wind noise leaks will occur at the door and window seals or at the sheet metal joints in the door or the door opening.

Symptom Chart

Condition Possible Sources Action
  • Dust and Water Leaks
  • Body sealer missing.
  • Opening in weldings or body joints.
  • Components not fully installed.
  • Components missing.
  • Components damaged.
  • REMOVE trim panel. CHECK for leaks and SEAL with appropriate sealer. ROAD TEST or WATER TEST for leaks. RECHECK for leaks; USE light under the vehicle with trim removed. CHECK interior of body at joints and weld lines.
  • Dust/Water Leaks at Floor Pan and Grommets
  • Missing or damaged plugs and/or grommets.
  • CHECK plugs for proper installation. REPLACE if necessary.
  • Door Drain Holes Collecting Water
  • Wind Noise, Air Entering Vehicle Through Small Holes in Body
  • Holes clogged with mud or road tar.
  • Leaks at door and window seals or sheet metal joints in doors or door openings
  • CLEAN drain holes of dirt and foreign material. CHECK drain holes regularly. TEST the system for normal operation
  • SEAL leaks with Silicone Gasket and Sealant F7AZ- 19554-EA meeting Ford specifications WSK-M2G343- A4. ROAD TEST.
  • Rattles
  • Loose objects in wells, pillars, and quarter panels.
  • Misalignment (if tightening bolts does not eliminate rattle).
  • Weatherstripping and/or anti-squeak material.
  • CHECK doors by carefully STRIKING underside of door with a rubber mallet. LISTEN for loose objects in door.

    REPAIR. TIGHTEN body bolts and screws.

  • ADJUST the alignment of the doors or panels.
  • APPLY additional sealer.

    INSTALL in proper location to eliminate rattle.

 

    Body Sealer Types And Applications
    Liquid Butyl Sealer HB Fuller E709-19554-B or equivalent meeting Ford Specification ESB-M4G162-A: Does not run. Is fast drying. Remains semi-elastic. Can be used for seam sealing o ...

    Front End Body Panels
    Torque Specifications Front End Body Panels The front end body panel components consist of the following: air deflectors cowl grille fenders fender splash shields hood hood hi ...

    Other materials:

    Lamp Assembly - Fog Lamp (GT)
    Removal 1. Raise and support the vehicle. 2. Remove the screw. 3. Partially lower the vehicle and remove the fog lamp assembly. 1. Disconnect the electrical connector. 2. Remove the two screws. 3. Remove the fog lamp assembly and replace the bul ...

    Reverse Sun Gear
    Disassembly   1. Remove the reverse clutch sun gear assembly and the No. 4 forward clutch hub bearing and race. 2. Remove the forward clutch sun gear assembly and the No. 5 forward clutch sun gear bearing and race. Assembly 1. The forward clutch ...

    Flywheel Runout Check
    Special Tool(s) Dial Indicator/Magnetic Base 100-D002 (D78P-4201-B) or equivalent 1. Mount the special tool so that the indicator contact point rides on the clutch disc contact surface. 2. Turn the flywheel (6375); if the runout exceeds the ...