Ford Mustang (1999-2004) Service Manual: Safety Belt Maintenance

WARNING: All safety belt assemblies include retractors, buckles, front seat belt buckle support assemblies (slide bar, if so equipped), shoulder belt height adjuster (if equipped), child safety seat tether bracket assemblies (if equipped) and attaching hardware should be inspected after any collision. Ford recommends new safety belt assemblies be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Safety belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted.

1. The safety belt assemblies should be periodically inspected to make sure that they have not become damaged and that they remain in correct operating condition, particularly if they have been subjected to severe stress.

2. Before installing the new safety belt assembly, the safety belt retaining areas must be inspected for damage and distortion. If the retaining points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity.

3. Install the new safety belt(s) using the appropriate instructions. Carry-out the Functional Test Procedure. For additional information, refer to Safety Belt System in this section.

Safety Belt With Anchor Plate Thread Damage

1. NOTE: The following is for 7/16-20 bolts only.

NOTE: The lap/shoulder safety belts are factory-installed in their correct locations. If the safety belts are removed for any reason, they must be installed; refer to removal and installation. The anchor bolts must be hand-started and then tightened to the correct torque specifications as noted in the Torque Specifications table in this section.

Remove the broken or stripped bolt.

2. Drill out the internal threads in the safety belt anchor plate with a 27/64 inch drill bit.

3. Rethread the anchor plate with a 1/2-13 tap.

4. Blow out the chips.

5. NOTE: New parts are to be used in place of the original parts; refer to the Parts Replacement Chart-Safety Belt with Damaged Weld Nut Anchor Plate Threads in Specifications in this section.

Install the attachment parts in the correct sequence. For additional information, refer to the procedure in this section. Install a new bolt, hand-tighten and then tighten to correct torque specifications as noted in the Torque Specifications table in this section.

Replacement of the Weld Nut and Reinforcement

1. NOTE: The following is for Coupe, Front and Rear, and Convertible rear only.

NOTE: If the safety belt anchor nuts or reinforcements are stripped or missing, a new nut/reinforcement plate must be installed.

Expose the suspect anchor point.

2. Drill out two 8 mm (0.32 in) (5/16 inch) diameter access holes adjacent to the weld nut clearance hole.

3. Thread a length of copper welding wire through the clearance hole and position to secure the weld nut and washer.

4. Use MIG wire feed welder and plug weld a 7/16 inch weld nut and standard washer in place at the two 8 mm (5/16 inch) holes.

5. Metal finish as necessary.

6. Install the restraint system.

7. Carry out the Functional Test. For additional information, refer to Safety Belt System in this section.

Safety Belt Procedure After a Collision

WARNING: All safety belt assemblies include retractors, buckles, front seat belt buckle support assemblies (slide bar, if so equipped), shoulder belt height adjuster (if equipped), child safety seat tether bracket assemblies (if equipped) and attaching hardware should be inspected after any collision. Ford recommends new safety belt assemblies be installed unless a qualified technician finds the assemblies show no damage and operate correctly. Safety belt assemblies not in use during a collision should also be inspected and new assemblies installed if either damage or incorrect operation is noted.

1. Before installing a new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be worked back to its original shape and structural integrity.

2. Install the new safety belt(s); refer to the procedure in this section. Carry-out the Functional Test. For additional information, refer to Safety Belt System in this section.

    Component Test
    Carry out the appropriate Functional Test(s) as determined in Inspection and Verification. Functional Test I (Buckle and Tongue) The safety belt buckle and tongue assembly must operate freely during ...

    Safety Belt Tongue Rotated on Belt
    1. Grasp the belt tongue and pull the belt webbing down to form a loop through the upper (longer and narrower) slot in the tongue. 2. Rotate and fold the belt webbing over itself within the slot to ...

    Other materials:

    Removal
    1. Remove the upper intake manifold. For additional information, refer to Upper Intake Manifold in this section. 2. Partially drain the cooling system. For additional information, refer to Section. 3. Relieve the fuel system pressure. For additional i ...

    Push Rod
    Removal CAUTION: Mark the components removed for correct location. 1. Remove the rocker arms (6564). For additional information, refer to Rocker Arm in this section. 2. Remove the push rods (6565). 3. Inspect the components. For additional information, ...

    Air Conditioning (A/C) System Check - Retail Procedure
    NOTE: This Retail Procedure is not eligible for claiming on Ford paid repairs (warranty and ESP). NOTE: The engine should be run at idle for 10 minutes with the air conditioning on and set to MAX A/C before carrying out this retail procedure. NOTE: Re ...