Door FORD MUSTANG 2003 Manual PDF

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
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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
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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
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Remove the lower fender bolts and, if equipped, remove the shims.
6. Through the door opening, remove the inner fender bolts.
7. Remove the radiator grille opening panel to fender bolts.
8. Remove the upper bolts and the fender.
9. NOTE: On the RH fender, feed the antenna cable through the fender opening.
To install, reverse the removal procedure. Klj . 2 ba
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SPECIFICATIONS
SECTION 501-
03: Body Closures 2003 Mustang Workshop Manual General Specifications
Item Specification
Premium Long Life Grease XG-1-
C or
XG -1-K ESA-
M1C75- B Silicone Lubricant (Aerosol) F5AZ-
19553-
AA ESR-
M13P4-A Multi-
Purpose Grease Spray XL-5 ESB-
M1C93- B Flowable air dry paintable caulk ESB-
M4G24- A Door clearance: bottom of the door to
the rocker panel 3.0-
7.0 mm (0.118- 0.275 in) parallel top to bottom within
2.0 mm (0.08 in) Door clearance: front and rear of the
door to the body 3.0-
7.0 mm (0.118- 0.275 in) parallel with the body opening
within 1.0 mm (0.04 in) Door flushness: door to the front fender -
1.0- 0.00 mm (- 0.04-0.00 in)
Torque Specifications Description Nm lb-
ft lb-
in Door latch striker plate bolts 25 18 —
Door hinge nuts and bolts 30 22 —
Luggage compartment lid hinge bolts 30 22 —
Luggage compartment lid hinge nuts 13 10 —
Rear spoiler nuts/screws 9 — 80 Klj . 1 ba
22003 Mustang Workshop Manual
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DESCRIPTION AND OPERATION
Body Closures
The body closures consist of the following components:
zdoor checks
z front door
z front door latch strikers
z front door hinges
z front door opening weatherstrips
z hood
z hood (Cobra) with heat extractor scoops
z hood (Mach I) with shaker opening
z hood heat extractor scoops (Cobra)
z hood hinges
z hood support rod
z hood weatherstrip
z luggage compartment lid
z luggage compartment lid hinges
z luggage compartment lid hydraulic lifts
z luggage compartment lid latch striker
z luggage compartment lid weatherstrip
SECTION 501-
03: Body Closures 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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GENERAL PROCEDURES
Hinge Adjustment
NOTE:
The door should be adjusted for even and parallel fit with the body opening and surrounding
panels as well as making sure that the anti- chuck pin is not binding on convertible models.
1. Remove the A- pillar lower trim panel.
2. Position the electrical connectors aside.
3. Loosen the lower front door hinge- to-body nut enough to permit movement.
4. Remove the fender. For additional information, refer to Section 501 - 02 .
5. Mark the position of the upper and lower front door hinges to the body to use as reference points.
6. Loosen the four upper and lower front door hinge- to-body bolts enough to permit movement.
SECTION 501-
03: Body Closures 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
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7. Adjust the front door to specification.
8.
NOTE: After adjusting the door hinge, verify that the door can be closed easily and fits tightly.
Tighten the front door hinge to body bolts.
9. Tighten the front door hinge to body nut.
10. Install the electrical connectors.
11. Install the A- pillar lower trim panel.
12. Install the fender. For additional information, refer to Section 501 - 02 . Klj . 2 ba
32003 Mustang Workshop Manual
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GENERAL PROCEDURES
Door Alignment
NOTE:
The door should be adjusted for even and parallel fit with the body opening and surrounding
panels as well as making sure that the anti- chuck pin is not binding on convertible models.
1. Mark the position of the front door hinges to the front door to use as reference points.
2. Loosen the front door hinge- to-front door bolts enough to permit movement.
3. Adjust the front door alignment to specification.
4. NOTE: After aligning the door, verify that the door can be closed easily and fits tightly.
Tighten the front door hinge- to-front door bolts.
SECTION 501-
03: Body Closures 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

GENERAL PROCEDURES
Striker Adjustment
NOTE:
After adjusting the door latch striker plate, verify that the door can be closed easily and fits
tightly.
1. Loosen the door latch striker plate bolts.
2. Reposition the door latch striker plate from side to side or up and down as necessary.
3. Tighten the door latch striker plate bolts.
4. Check the adjustment. Repeat the procedure as necessary.
SECTION 501-
03: Body Closures 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...