belt FORD MUSTANG 2003 Workshop Manual

Functional Test III (System Road Test Inspection)
1. NOTE: If the RH or the rear safety belts are to be tested, the assistance of a passenger is
required.
Fasten the safety belts and proceed to a safe area.
2. Attain a speed of 8 km/h (5 mph).
3. WARNING: The driver and passenger must be prepared to brace themselves if the
retractor does not lock.
Test the safety belts. 1. Grasp the shoulder harness and prepare to lean forward.
2. WARNING: The maximum brake application should be on dry concrete or
equivalent hard surface, NEVER on wet pavement or gravel.
WARNING: The driver and passenger must be prepared to brace themselves
in the event the retractor does not lock.
Make a maximum brake application without a skid.
3. NOTE: Do not jerk on the safety belt webbing when carrying out this test. Lean forward slightly when the brake application is made.
4. The safety belts should lock up with minimum webbing extension.
5. If there is a lockup of both shoulder straps, the safety belt assemblies are functioning correctly. Should either or both retractors fail to lock up at the 8 km/h (5 mph) speed, repeat the test at a
constant 24 km/h (15 mph) speed. (This test must be carried out with the assistance of a RH
front or rear passenger if the RH front or rear safety belts are to be tested).
6. CAUTION: Before installing a new safety belt assembly, inspect the mounting area
for damage and distortion. If the retractor of a new safety belt assembly has been bolted
into a damaged or distorted mounting area, the retractor could be warped and may not
function. If this is the case, remove the retractor and return the sheet metal to the
original configuration and install another complete safety belt assembly.
If the retractors do not lock up at the 24 km/h (15 mph) test, return the vehicle for service of
malfunctioning safety belts.
Functional Test IV (Automatic Locking Retractor) WARNING: After any vehicle collision, the safety belt system at all outboard seating
positions (except driver, which has no "automatic locking retractor" feature) must be checked
by a qualified technician to verify that the "automatic locking" feature for child seats is still
functioning correctly, in addition to other checks for correct safety belt system function. A new
safety belt and retractor assembly must be installed if the safety belt assembly's "automatic
locking retractor" feature or any other safety belt function is not operating correctly when
checked according to the procedures in the workshop manual. Failure to install a new safety
belt and retractor assembly could increase the risk of injury in collisions.
1. Position the seat back into the full up position. Klj . 3 ba
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2. Position the height adjuster in the full down or up position.
3. Latch the seat belt buckle and tongue assembly.
4. Pull the shoulder belt out until the automatic locking retractor (ALR) feature is activated.
5. Release the shoulder belt and allow it to retract until it stops.
6. Pull on the shoulder belt to check that the belt has remained in the ALR mode. If the belt is not
locked, install a new safety belt and retractor assembly.
7. Unlatch the safety belt tongue from the buckle and allow the safety belt to retract to its stowed position.
8. Pull the shoulder belt to verify the retractor assembly has converted automatically out of the ALR mode. If the shoulder belt remains locked in the stowed position, install a new safety belt
and retractor assembly. Klj . 4 ba
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GENERAL PROCEDURES
Safety Belt Cleaning
1. WARNING: Do not bleach or re- dye the webbing, as the webbing may weaken.
Clean the safety belt webbing only with a mild soap solution recommended for cleaning
upholstery or carpets. Follow the instructions provided with the soap.
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GENERAL PROCEDURES
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.
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GENERAL PROCEDURES
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.
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GENERAL PROCEDURES
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.
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GENERAL PROCEDURES
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.
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GENERAL PROCEDURES
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 remove the twist.
3. Pull the excess belt webbing back through the upper slot in the belt tongue.
4. Grasp the belt tongue and pull the belt webbing up to form a loop through the low slot in the tongue.
5. Rotate and fold the belt webbing over itself within the slot to remove the twist.
6. Pull the excess belt webbing through the slot.
7. NOTE: Dual slot tongue shown; single slot tongue is similar.
The safety belt tongue should face inward when completed.
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REMOVAL AND INSTALLATION
Retractor —
Front Seat Safety Belt, Coupe
Removal 1. Remove the quarter trim panel (31012). For additional information, refer to Section 501 - 05 .
2. Using the special tool, remove the bolt and the safety belt retractor. zRemove the mastic seal.
3. Using the special tool, remove the safety belt anchor bolt.
4. Using the special tool, remove the D- ring bolt.
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Torx Bit, Safety Belt Bolt
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Installation
NOTE:
Make sure the retractor tongue faces inboard.
NOTE: Make sure the safety belt is not twisted.
1. The shipping clip must remain attached prior to the installation of the retractor into the vehicle.The clip must be removed after the retractor is installed.
2. Position the safety belt anchor. Using the special tool, install the safety belt bolt.
3. Install a new mastic seal around the safety belt retractor before installing the retractor in the vehicle.
4. Position the safety belt retractor. Using the special tool, install the bolt. Klj . 2 ba
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