FORD MUSTANG 2003 Workshop Manual

SPECIFICATIONS
SECTION 501-
00: Body System — General Information 2003 Mustang Workshop Manual General Specifications
Item Specification
Adhesives
Weatherstrip and Rubber Adhesive E8AZ-19552-
A ESB-
M2G14- A Lubricants
Silicone Lubricant C0AZ-19553-
AA ESR-M13P4-
A Sealers
HB Fuller E709-19554-
B ESB-
M4G162- A 3M Strip Caulk-
Black 051135-08578 ESB-
M4G32- A Silicone Gasket and Sealant F7AZ-19554-
EA WSK-
M2G343- A4 Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

DESCRIPTION AND OPERATION
Body
Body and Sheet Metal
The body:
zIs a unibody open cowl structure.
z Is constructed of a lightweight, all- steel material with removable bolted hood (16612), front
fenders (16005), doors, and luggage compartment lid.
SECTION 501-
00: Body System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

DESCRIPTION AND OPERATION
Insulation
Insulation is comprised of urethane, PVC, and recycled felt. Insulation is installed:
zUnder the roof panel (50202).
z Above and below the instrument panel (04304).
z On the cowl sides.
z Over the front and rear floor areas.
z On a Coupe, in the B and C- pillar sections.
z Under the hood.
SECTION 501-
00: Body System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

DESCRIPTION AND OPERATION
Body Sealer Types And Applications
Liquid Butyl Sealer
HB Fuller E709-19554-
B or equivalent meeting Ford Specification ESB-M4G162- A:
z Does not run.
z Is fast drying.
z Remains semi-elastic.
z Can be used for seam sealing on the floorpan, wheelhouse, body rocker panels, door openings,
and drip rails.
Caulking Cord
3M Strip Caulk- Black 051135-08578 or equivalent meeting Ford specification ESB-M4G32- A:
z Is a heavy- bodied, plastic base with a filler.
z Is commonly known as perma-gum.
z Is used on spot- welds holes, around moulding clips, and between surfaces not sealed with a
gasket.
Weatherstrip Adhesive
Weatherstrip and Rubber Adhesive E8AZ-19552- A or equivalent meeting Ford specification ESB-
M2G14- A:
z Is a quick drying, strong adhesive designed to hold weatherstripping onto all body panels and
surrounding metal.
Silicone Lubricant
Silicone Lubricant C0AZ-19553-AA meeting Ford specification ESR- M13P4-A:
z Is used to keep the door and the window weatherstrip pliable and soft.
z Should be applied to the weatherstrip at every lubrication period.
z Makes the door easier to close.
z Retards weatherstrip squeaks.
z Retards weatherstrip wear.
z Helps retain door window alignment by reducing friction between the glass frame and the rubber
weatherstrip.
z Should not be used prior to painting.
SECTION 501-
00: Body System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

Klj . 2 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

DIAGNOSIS AND TESTING
Body System
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 SECTION 501-
00: Body System — General Information 2003 Mustang Workshop Manual Symptom Chart
Condition
Possible Sources Action
z Dust and
Water Leaks z
Body sealer missing.
z Opening in weldings
or body joints.
z Components not fully
installed.
z Components missing.
z Components
damaged. z
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.
z Dust/Water
Leaks at Floor
Pan and
Grommets z
Missing or damaged
plugs and/or
grommets. z
CHECK plugs for proper
installation. REPLACE if
necessary.
z Door Drain
Holes
Collecting
Water z
Holes clogged with
mud or road tar. z
CLEAN drain holes of dirt and
foreign material. CHECK drain
holes regularly. TEST the
system for normal operation. Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

z
Wind Noise,
Air Entering
Vehicle
Through Small
Holes in Body z
Leaks at door and
window seals or
sheet metal joints in
doors or door
openings. z
SEAL leaks with Silicone
Gasket and Sealant F7AZ-
19554- EA meeting Ford
specifications WSK-M2G343-
A4. ROAD TEST.
z Rattles zLoose objects in
wells, pillars, and
quarter panels.
z Misalignment (if
tightening bolts does
not eliminate rattle).
z Weatherstripping
and/or anti- squeak
material. z
CHECK doors by carefully
STRIKING underside of door
with a rubber mallet. LISTEN
for loose objects in door.
REPAIR. TIGHTEN body bolts
and screws.
z ADJUST the alignment of the
doors or panels.
z APPLY additional sealer.
INSTALL in proper location to
eliminate rattle. Klj . 2 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

SPECIFICATIONS
SECTION 501-
02: Front End Body Panels 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
ft lb-
in Hood latch support screws 12 9 —
Hood latch retaining screws 12 9 —
Hood latch control handle and cable retaining screws 3 — 27
Hood latch support nuts 10 — 89
Fender bolts 12 9 —
Grille opening panel bolts 3 — 27
Rear hood hinge to body bolts 9 — 80
Front hood hinge to body bolts 13 10 — Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

DESCRIPTION AND OPERATION
Front End Body Panels
The front end body panel components consist of the following:
zair deflectors
z cowl grille
z fenders
z fender splash shields
z hood
z hood hinges
z hood weatherstrip
z radiator grille opening panel
SECTION 501-
02: Front End Body Panels 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Fender
Removal and Installation
1. On the RH fender, remove the antenna base. 1. Remove the antenna base cap.
2. Remove the screws.
3. Remove the antenna base.
4. Disconnect the antenna cable from the antenna base.
2. Remove the front bumper cover. For additional information, refer to Section 501 - 19 .
3. Remove the screw, the two pin- type retainers and the front rocker panel moulding.
4. Remove the fender splash shield screw. 5. NOTE: Position the fender splash shield aside. SECTION 501-
02: Front End Body Panels 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...