Fulltext TSBs

Technical Service Bulletins

TSB
03-26-4
  • BODY – REAR DOOR PANEL – WAVY APPEARANCE IN COLD WEATHER – LOUD RINGING UPON CLOSING DOOR – RATTLE INSIDE OF DOOR – VEHICLES BUILT BEFORE 11/12/2003
  • NOISE – REAR DOOR PANEL – WAVY APPEARANCE IN COLD WEATHER – LOUD RINGING UPON CLOSING DOOR – RATTLE INSIDE OF DOOR – VEHICLES BUILT BEFORE 11/12/2003
Publication Date: December 22, 2003

FORD:
2004 F-150

ISSUE:

On some 2004 F-150 Supercab vehicles built before 11/12/2003, the rear door panel outer surface may exhibit a wavy appearance in cold weather. The door may also exhibit a loud ringing upon closing, or a rattle noise may be present inside the door.

ACTION:

To service, install a Permacel Mastic Patch (4L3Z-18203A16-AA) to the door outer panel. Refer to the following Service Procedure.

SERVICE PROCEDURE

  1. Remove the rear door trim panel per Section 501-05 of the Workshop Manual.
  2. Peel back the water shield to access the inside of the door.
  3. Inspect for the presence of mastic material on the door outer panel. If none is present, proceed to Step 7.

    NOTE:THE MASTIC MATERIAL MAY HAVE FALLEN DOWN INTO THE DOOR. REMOVE ANY LOOSE PIECES FROM THE BOTTOM OF THE DOOR.

  4. From the outside of the door, place an Infra-Red paint curing lamp 46cm (18″) from the door sheet metal surface in the area of the mastic patch. Heat the door for 3-7 minutes at 180F.
  5. Remove the heated mastic material from inside the door using a wide putty knife.
  6. Remove any loose mastic pieces from the bottom of the door.
  7. Apply Motorcraft PM-12-A Low Temperature Anti-Corrosion Coating to the original location of the mastic material.

    NOTE:THERE WILL BE A VISIBLE WITNESS MARK (UNPAINTED PORTION) INSIDE THE DOOR INDICATING THE LOCATION FOR THE NEW MASTIC MATERIAL.

  8. Install Permacel Mastic Patch (4L3Z-18203A16-AA) over the original location of the mastic. Press the mastic patch thoroughly in place, especially on edges and corners.
  9. Reinstall the door watershield.
  10. Reinstall the door trim panel.

PART NUMBERPART NAME
4L3Z-18203A16-AAMastic Patch
PM-12-ALow Temp Anti-Corrosion Coating

OTHER APPLICABLE ARTICLES:

NONE

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage


NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company’s on-line technical resources.

Copyright 2003 Ford Motor Company