Page 1 of 29 2003 Ford Thunderbird 3.9L Eng WATER LEAKS - REMOVABLE ROOF AND CONVERTIBLE TOP - SERVICE TIPS TECHNICAL SERVICE BULLETIN Reference Number(s): 04-9-5, Date of Issue: May 17, 2004 FORD: 2002-2005 THUNDERBIRD Superceded Bulletin(s): 02-21-14, Date of Issue: October 28, 2002 DESCRIPTION BODY - WATER LEAKS - REMOVABLE ROOF AND CONVERTIBLE TOP - SERVICE TIPS NOTE: This article supersedes TSB 02-21-14 to update the model years and service procedure. ISSUE Some 2002-2005 Thunderbird vehicles may exhibit water leaks with the removable roof installed or convertible top in the raised position. ACTION This article will address the most common areas of water leaks associated with the removable roof and convertible top and will assist in making an effective repair. Refer to the following service tips. SERVICE PROCEDURE NOTE: THUNDERBIRD ROOF SEALING SYSTEMS ARE DESIGNED TO PREVENT WATER FROM ENTERING THE VEHICLE DURING NORMAL EVENTS OF RAIN. WATER INGRESS RESULTING FROM EXPOSURE TO A HIGH PRESSURE WASHER (POWER WASHER) OR AUTOMATED CAR WASH THAT USES HIGH PRESSURE WASHING EQUIPMENT SHOULD BE CONSIDERED NORMAL. NOTE: A REMOVABLE ROOF STORAGE CART MUST BE AVAILABLE TO PERFORM THE SERVICE PROCEDURES IN THIS ARTICLE. REMOVABLE ROOF AND REMOVABLE ROOF WEATHERSTRIP PRELIMINARY POSITION CHECK

Page 2 of 29 NOTE: ONLY WEATHERSTRIPS THAT ARE PHYSICALLY DAMAGED SHOULD BE REPLACED. MOST WATER LEAKS CAN BE REPAIRED BY ADJUSTMENT PROCEDURES OUTLINED IN THIS ARTICLE. 1. Check that all weatherstrips are positioned correctly on the removable roof, vehicle header and a-pillar (Fig 1 and Fig 2 ). Fig 1: Removable Roof A-Pillar Weatherstrip Position

Page 3 of 29 Fig 2: Roof Weatherstrip Position In Door Opening 2. Check for the proper 7 mm gap at each a-pillar corner between the chrome windshield header molding and the removable roof (Fig 3 ).

Page 4 of 29 Fig 3: 7 mm Gap At A-Pillar Corner a. If the gap between the chrome windshield header molding and removable roof is correct then proceed to the service procedure section that refers to the leak location on vehicle. b. If the gap is not correct then proceed to Step 3. 3. Remove the removable roof. 4. Remove the two (2) trim covers at the b-pillar area to access the two (2) removable roof top locator brackets (Workshop Manual Section 501-00). 5. Scribe each removable roof locator bracket position for reference (Fig 4 ).

Page 5 of 29 Fig 4: Removable Roof Locator Bracket Position 6. Loosen the removable roof locator bracket 10 mm bolts (two (2) per bracket) and adjust the locator brackets forward or rearward as necessary to obtain the proper 7 mm gap between the chrome windshield header molding and the removable roof (Fig 3 and Fig 4 ). 7. It may also be necessary to adjust the front location tab/block on the removable roof by loosening the three (3) Torx bolts on each block (Fig 5 ).

Page 6 of 29 Fig 5: Front Location Tab/Block On Removable Roof 8. Reinstall the removable roof and recheck for the proper 7 mm gap between the chrome windshield header molding and the removable roof (Fig 3 ). Repeat Steps 4-7 until gap is correct. 9. Water test vehicle using only normally pressurized tap water from a standard sized garden hose. a. If leak is no longer present return the vehicle to the customer. b. If leak is still present proceed to the section of the service procedure that refers to the leak location on vehicle.

Page 7 of 29 REMOVABLE ROOF WATER LEAKS AT A-PILLAR (FRONT UPPER CORNER OF DOOR GLASS) 1. Verify the water leak condition. For testing, use only normally pressurized tap water from a standard size garden hose. 2. Reset the power window short drop function. Refer to the Owner's Guide. 3. Retest for water leak. a. If leak is no longer present return the vehicle to the customer. b. If leak is still present then proceed to Step 4. 4. Remove the removable roof and check that the weatherstrip corners at the top of the a-pillars near the windshield weatherstrips are seated/positioned correctly (Fig 6 ). Fig 6: Weatherstrip Corner At Top Of A-Pillar a. If gaps are present, correct by pushing/repositioning weatherstrip as needed. Reinstall the roof and water test. If the leak is corrected return vehicle to customer.

Page 8 of 29 b. If weatherstrips were seated correctly, proceed to Step 5. 5. Water, which enters the vehicle between the side weatherstrip and the door glass near the top of the a-pillar, can be repaired by adding seal stuffer, part number 2W6Z- 76025B52-AA. The part package contains 2 stuffers. Install one stuffer on each side of the vehicle following Steps 5-9. NOTE: SOME VEHICLES MAY ALREADY HAVE THE SEAL STUFFER INSTALLED. IF SEAL STUFFER IS ALREADY INSTALLED VERIFY THAT IT HAS BEEN POSITIONED CORRECTLY PER STEP 9. IF SEAL STUFFER IS NOT POSITIONED CORRECTLY REMOVE AND REPLACE WITH A NEW SEAL STUFFER FOLLOWING STEPS 5-9. 6. Remove the roof from the vehicle and place in the removable roof storage cart. 7. Dry all moisture and clean all dirt and debris from the weatherstrips on the roof. 8. Apply 3-4 small evenly placed dabs of Ford Trim and Weatherstrip Adhesive, part number TA-14, to one side of the seal stuffer. Do not coat the entire stuffer with adhesive. 9. Position the seal stuffer behind the secondary seal approximately 20 mm rearward from the front edge of the seal. For best results have an assistant open the weatherstrip so proper placement can be obtained (Fig 7 ) (the primary weatherstrip has been removed in the figure for clarity).

Page 9 of 29 Fig 7: Positioning Seal Stuffer Behind Secondary Seal 10. Install the roof and water test to verify the repair. 11. If water leak continues in the same location, the weatherstrips may require adjustment or the door glass may not be fully rolling up into the weatherstrip, Proceed to REMOVABLE ROOF LEAKS AROUND DOOR GLASS WEATHERSTRIPS. REMOVABLE ROOF LEAKS AROUND DOOR GLASS WEATHERSTRIPS Adjusting or repositioning the weatherstrips may repair water, which enters the vehicle between the side weatherstrips and the door glass.

Page 10 of 29 1. First, reset the power window short drop function. Refer to the Owner's Guide. Verify that the weatherstrips along the glass are uniformly pressing against the door glass. This can be done by moistening the weatherstrips with water and closing the door. The wet weatherstrips will clearly show their contact pattern against the glass. 2. Where no contact pattern is present, firmly grasp and pull the weatherstrip to the desired location to achieve a uniform seal against the glass. The weatherstrip is attached to metal flanges on the roof, which will bend slightly. a. If leak condition is corrected return vehicle to customer. b. If adjustments do not correct the condition, the door glass may not be fully rolling up into the weatherstrip, proceed to Step 3. 3. Make certain the windows are capable of completely seating into the weatherstrip. a. Open the door and manually trip the door latch closed. This will raise the glass with the short drop function. b. Measure the distance between the peaked edge on the rear of the door glass to the top of the belt molding seal. If greater than 9.5 mm (3/8"), the glass is not rolling up fully into the weatherstrips, proceed to Step 4. If 9.5 mm (3/8") or less, the glass is lifting properly. Verify weatherstrips are still positioned correctly (Fig 8 ).

Page 11 of 29 Fig 8: Measuring Between Door Glass & Belt Molding Seal 4. The glass may not mechanically roll up far enough to seal. a. Keep door open, and the window in the raised position from the short drop feature. b. Remove the door trim panel to access the rear glass adjustment nut. Refer to Workshop Manual, Section 501-05. c. Loosen the rear 10 mm regulator clamp bolt and pull upward on the glass until a maximum of 9.5 mm (3/8") can be measured between the peaked edge on the rear edge of the door glass and the top of the belt molding seal (Fig 8 ).

Page 12 of 29 d. Torque the bolt to 12 N.m (9 lb-ft). e. Assemble the door trim panel; flip the latch closed to drop the glass, and water test. f. If water leaks are corrected, return vehicle to customer. g. If water leak continues, verify weatherstrips are still positioned correctly then inspect and replace any damaged weatherstrips as necessary. REMOVABLE ROOF WATER LEAKS ALONG WINDSHIELD HEADER 1. Verify the two (2) roof T40 a-pillar attaching screws are torqued to 9 N.m (80 lb-in) and that latch handles below the porthole windows are fully engaged. 2. If fasteners are found loose or latches were not engaged, tighten/latch then water test. a. If leak is repaired, return vehicle to customer. b. If leaking continues proceed to Step 3. 3. Isolate source of leak by first applying masking tape over the windshield header seal. The masking tape should overlap onto the chrome windshield header molding and onto the roof header trim bead (Fig 9 ). Fig 9: Windshield Header Molding And Seal

Page 13 of 29 4. Remove the interior header trim panel from the removable roof by grasping and firmly pulling down the panel. This will aid in locating the source area of the water leak. 5. Run normally pressurized tap water from a standard size garden hose over the taped off area. a. If the leak is no longer present proceed to Step 6. b. If the leak is still present proceed to Step 12. 6. Remove the removable roof. 7. Inspect windshield header seal for damage. a. If seal is damaged repair as necessary and perform water test. Return vehicle to customer if leak has been repaired. b. If seal is OK then proceed to Step 8. 8. Remove the chrome windshield header molding and the left and right chrome a-pillar moldings and inspect seams in windshield frame (refer to Workshop Manual Section 501-00 for removal instructions). 9. Seal seams as necessary with Silicone Gasket and Sealant, part number TA-30. 10. Reinstall chrome windshield header molding and the left and right chrome a-pillar moldings. 11. Reinstall the removable roof and verify the repair. a. If leak is still present proceed to Step 12. b. If leak is no longer present return vehicle to customer. 12. Apply masking tape over removable roof to roof header trim bead seam and over removable roof to drip rail molding seam (Fig 10 ).

Page 14 of 29 Fig 10: Removable Roof To Roof Header Trim Bead Seam 13. Run normally pressurized tap water from a standard size garden hose over the taped off area. 14. If water is not entering the vehicle during this test, it may be penetrating between the removable roof and roof header trim bead or between the removable roof and the removable roof drip rail molding. 15. Remove the roof and carefully set on the removable roof storage cart. 16. Check that the weatherstrip corners at the top of the a-pillars near the windshield header weatherstrips are seated correctly (Fig 11 ).

Page 15 of 29 Fig 11: Weatherstrip Corner At Top Of A-Pillar a. If gaps are present, correct by pushing/repositioning the weatherstrip as needed. Reinstall roof and water test. If leak is corrected return vehicle to customer. b. If weatherstrips were seated correctly, proceed to Step 17. 17. On the side where the roof leak is present (RF or LF corner), loosen screws on the underside of roof that attach the roof header trim bead (Fig 12 ).

Page 16 of 29 Fig 12: Roof Header Trim Bead On Underside Of Roof 18. Starting on the top side of removable roof, apply a small bead of clear silicone rubber, part number TA-32, between the roof header trim bead and the removable roof starting in the corner where the leak is inward about 20.5 cm (8") toward the center of the roof. (Fig 13 ).

Page 17 of 29 Fig 13: Silicone Application To Roof Header Trim Bead Seam NOTE: USE A SOFT FLEXIBLE PLASTIC OR RUBBER PADDLE (SUCH AS A BODY FILLER SPREADER) TO GENTLY LIFT UP ON TRIM MOLDING WHILE APPLYING THE SEALANT BEAD. CAUTION: DO NOT USE TOOLS TO DIRECT THE SILICONE THAT WILL DAMAGE THE PAINT. TEST TOOL ON A SCRAP PIECE OF PAINTED SHEET METAL FIRST TO CHECK FOR EVIDENCE OF PAINT DAMAGE.

Page 18 of 29 19. Immediately clean the excess silicone from the roof with a damp cloth. 20. Repeat application of clear silicone rubber, part number TA-32, between the drip rail molding and removable roof starting in the corner where the leak is back to about the point where side window starts to curve down at b-pillar (Fig 13 ). 21. Immediately clean the excess silicone from the roof with a damp cloth. 22. Working on the underside of the removable roof, apply a small bead of clear silicone rubber, part number TA-32, between the roof header trim bead and the removable roof (Fig 12 ). 23. Retighten the roof header trim bead screws that were loosened in Step 17 of this procedure (Fig 12 ). 24. Secure rubber flap down on underside corner where leak is of removable roof with Ford Trim and Weatherstrip Adhesive TA-14 (Fig 12 ). 25. Reinstall the removable roof and reset the power window short drop function. Refer to the Owner's Guide. NOTE: MAKE SURE THAT THE REMOVABLE ROOF HAS THE PROPER 7 MM GAP BETWEEN THE CHROME WINDSHIELD HEADER MOLDING AND THE REMOVABLE ROOF (Fig 14 ). Fig 14: 7 mm Gap At A-Pillar Corner

Page 19 of 29 26. Water test with normally pressurized tap water through a standard size garden hose to verify the repair. CONVERTIBLE TOP WATER LEAKS AROUND DOOR GLASS 1. Verify the water leak. Direct normally pressurized tap water from a standard size garden hose around the effected door glass. 2. Reset the power window short drop function. Refer to the Owner's Guide for additional information. 3. Retest for water leak. a. If water leak has been resolved return vehicle to customer. b. If water leak is still present then proceed to Step 4. 4. Check that the weatherstrips up the a-pillar, at the corner of the a-pillar and windshield, and along the convertible top that seals the door glass are not damaged and are positioned correctly. Adjust/reposition weatherstrips as needed and water test (Fig 15 -Fig 18 ). a. If leak condition is corrected return vehicle to customer. b. If leak is not corrected proceed to Step 5.

Page 20 of 29 Fig 15: Convertible Top Weatherstrip Inside A-Pillar

Page 21 of 29 Fig 16: Gap Between First & Second Convertible Top Weatherstrip

Page 22 of 29 Fig 17: Gap Between Second & Third Convertible Top Weatherstrip

Page 23 of 29 Fig 18: Third Convertible Top Weatherstrip At Door Opening Weatherstrip NOTE: ONLY WEATHERSTRIPS THAT ARE PHYSICALLY DAMAGED SHOULD BE REPLACED. FOLLOWING THE STEPS IN THIS ARTICLE THAT PROVIDE ADJUSTMENT DETAILS CAN REPAIR MOST WATER LEAKS. 5. Roll down the windows and operate the convertible top down and back up. Once the top is at the windshield header and the pump motor begins to "stall", keep the button depressed for 2-3 seconds additional before latching the top. If the top is not completely positioned up, the top frame and weatherstrips will not be positioned correctly. Roll the windows up and water test. a. If leak condition is corrected return vehicle to customer. b. If leak is not corrected proceed to Step 6.

Page 24 of 29 6. Check for excessive gaps between the weatherstrips on the convertible top. Adjust the position of the weatherstrips on their mounting flange, or bend the mounting flange as needed to correct (Fig 15 -Fig 18 ). a. If leak condition is corrected return vehicle to customer. b. If leak is not corrected proceed to Step 7. 7. Lower the convertible top and check that the weatherstrip corners at the top of the a-pillars near the windshield header weatherstrips are seated/positioned correctly (Fig 19 ). Fig 19: Weatherstrip Corner At Top Of A-Pillar a. If gaps are present, correct by pushing/repositioning the weatherstrip as needed. Raise the roof and water test. If leak condition is corrected return vehicle to customer. b. If weatherstrips were seated correctly proceed to Step 8. 8. Make certain the windows are capable of completely seating into the weatherstrip.

Page 25 of 29 a. Raise the roof. Open the door and manually trip the door latch closed. This will raise the glass with the short drop function. b. Measure the distance between the peaked edge on the rear of the door glass to the top of the belt molding seal. If greater than 9.5 mm (3/8"), the glass is not rolling up fully into the weatherstrips, proceed to Step 12. If 9.5 mm (3/8") or less, proceed to Step 9 (Fig 20 ). Fig 20: Measuring Between Door Glass & Belt Molding Seal 9. Lift the outside door handle and trip the door latch open, which will drop the door glass. Close the affected door and measure and record the distance between the silkscreen on the door glass and the top of the belt molding seal. The measurement distance is not critical. The rule in the figure is for reference (Fig 21 ).

Page 26 of 29 Fig 21: Measuring Between Silkscreen & Belt Molding Seal 10. Open the affected door. Exert light hand pressure against the outside of the glass. Shut the door with normal force and keep pressure on the glass until the short-drop function raises the glass into the weatherstrip. Again measure between the silkscreen and the top of the belt molding seal (Fig 21 ). 11. If measurement is now greater than observed in Step 8, proceed to Step 13. If measurement stayed the same, proceed to Step 12. 12. The glass may not mechanically be able to roll up far enough to seal. a. Raise the roof. Open the affected door and command the system to roll the glass up with the short-drop feature. This is done by manually tripping the door latch. b. Remove the door trim panel to access the rear glass adjustment nut. Refer to Workshop Manual, Section 501-05. c. Loosen the rear 10 mm regulator clamp bolt and pull upward on the glass until a maximum of 9.5 mm (3/8") can be measured between the peaked edge on the rear of the door glass to the top of the belt molding seal.

Page 27 of 29 d. Torque the bolt to 12 N.m (9 lb-ft). e. Assemble the door trim panel; flip the door latch open to drop the glass and water test. f. If leak condition is corrected return vehicle to customer. g. If leak is not corrected proceed to Step 13. 13. The window motor may be stalling before the glass can properly seal. Strike "down and in" along the stitch bead on the edge of the convertible top, starting from the a-pillar area back approximately 50 cm (20") with a rubber mallet. This area is where the top of the glass penetrates a U-shaped channel in the weatherstrip. If the weatherstrip flange on the convertible top is not rolled inboard enough, the door glass will not properly enter the weatherstrip (Fig 22 ). Fig 22: Reshaping Weatherstrip Flange With Mallet 14. After the adjustment in Step 13 is made, normally open and close the door checking that the glass is rolling all the way up into the weatherstrip then water test. a. If leak condition is corrected return vehicle to customer. b. If leak is not corrected proceed to Step 15. 15. If the glass is still not fully entering the weatherstrips, adjust the channel in the rear portion of the second weatherstrip "up" to allow closure. This area of the weatherstrip is

Page 28 of 29 where it transitions from the channel along the roof to a compression seal along where the b-pillar would be present. Use the handle of a rubber mallet to bend the weatherstrip and convertible top flange "up" then water test (Fig 23 ). a. If leak condition is corrected return vehicle to customer. b. If leak is not corrected proceed to Step 16. Fig 23: Weatherstrip Transition From Roof To B-Pillar 16. Check that the weatherstrips are uniformly pressing against the door glass. This can be done by moistening the weatherstrips with water and closing the door. The wet weatherstrips will clearly show their contact pattern against the glass. This is critical along the rearward slope of the glass (b-pillar). 17. The weatherstrips are positioned on metal mounting flanges that are part of the convertible top frame. These flanges may be bent slightly to improve the weatherstrip pattern. To adjust, simply grasp the weatherstrip and move it inboard or outboard to improve contact against the glass. PARTS INFORMATION PARTS INFORMATION Part Number TA-14 Part Name Weatherstrip Adhesive

Page 29 of 29 TA-30 TA-32 2W6Z-76025B52-AA Silicone Sealant Clear Silicone Rubber Hard Top Seal Stuffer WARRANTY INFORMATION WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage.