2003 FORD MUSTANG sensor

NOTE:
If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the air bag system must be deactivated.
NOTE: Restraint system diagnostic tools MUST be installed under the seats in the seat side air bag (if
equipped) and safety belt pretensioner (if equipped) to floor connectors.
NOTE: Diagnostics or repairs are not to be performed on a seat equipped with a seat side air bag with
the seat in the vehicle. Prior to attempting to diagnose or repair a seat concern when equipped with a
seat side air bag, the seat must be removed from the vehicle and the restraint system diagnostic tools
must be installed in the seat side air bag electrical connectors. The restraint system diagnostic
tools must be removed prior to operating the vehicle over the road.
NOTE: After diagnosing or repairing an SRS, the restraint system diagnostic tools must be
removed before operating the vehicle over the road.
NOTE: After diagnosing or repairing a seat system, the restraint system diagnostic tools must be
removed before operating the vehicle over the road.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
1. WARNING: To avoid accidental deployment and possible personal injury, the
backup power supply must be depleted before repairing or replacing any front or side air
bag supplemental restraint system (SRS) components and before servicing, replacing,
adjusting or striking components near the front or side air bag sensors, such as doors,
instrument panel, console, door latches, strikers, seats and hood latches.
Please refer to the appropriate vehicle shop manual to determine location of the front air
bag sensors.
The side air bag sensors are located at or near the base of the B- pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and
wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if
equipped).
Disconnect the battery ground cable and wait at least one minute. For additional information,
refer to Section 414 - 01 .
2. Remove the steering column opening lower finish panel. 1. Remove the screws.
2. Pull out to release the retaining clips and remove the steering column opening lower finish panel.
3. Remove the steering column opening lower reinforcement. 1. Remove the bolts.
2. Remove the steering column opening lower reinforcement. Klj . 2 ba
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GENERAL PROCEDURES
Weld Nut Repair
—"J" Nut, Restraints Control Module
(RCM)
WARNING: To avoid accidental deployment and possible personal injury, the backup
power supply must be depleted before repairing or replacing any front or side air bag
supplemental restraint system (SRS) components and before servicing, replacing, adjusting or
striking components near the front or side air bag sensors, such as doors, instrument panel,
console, door latches, strikers, seats and hood latches.
Please refer to the appropriate vehicle shop manual to determine location of the front air bag
sensors.
The side air bag sensors are located at or near the base of the B- pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at
least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
NOTE: There are two procedures to repair a vehicle having missing restraints control module attaching
weld nut(s). Read both procedures before proceeding with the repair.
NOTE: If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure.
Weld nuts must be installed as outlined in Weld Nut Repair — Missing Weld Nut, Restraints Control
Module (RCM).
NOTE: The following procedure applies to vehicles that have a rectangular hole in the sheet metal that
is in close proximity to the missing weld nut.
1. Obtain a "J" nut (part number N623332- S301) or any of the following optional "J" nuts (part
numbers: N623342- S101, N800854-S100, N800925- S100).
2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327- S190) or equivalent.
3. Install the "J" nut through the rectangular hole in the sheet metal.
4. NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet
metal.
Install the crash sensor.
5. Tighten the attaching screws to specification. For additional information, refer to Torque Specifications in this section.
SECTION 501-
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GENERAL PROCEDURES
Weld Nut Repair —
Missing Weld Nut, Restraints Control
Module (RCM)
WARNING: To avoid accidental deployment and possible personal injury, the backup
power supply must be depleted before repairing or replacing any front or side air bag
supplemental restraint system (SRS) components and before servicing, replacing, adjusting or
striking components near the front or side air bag sensors, such as doors, instrument panel,
console, door latches, strikers, seats and hood latches.
Please refer to the appropriate vehicle shop manual to determine location of the front air bag
sensors.
The side air bag sensors are located at or near the base of the B- pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at
least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
NOTE: There are two procedures to repair a vehicle having missing restraints control module attaching
weld nut(s). Read both procedures before proceeding with the repair.
NOTE: If two or more weld nuts are missing, do not install the "J" nuts as outlined in Weld Nut Repair
—" J" Nut, Restraints Control Module (RCM). Weld nuts must be installed as outlined in this
procedure.
NOTE: Radiator support repair shown, others are similar.
1. Obtain a 6 mm (0.24 in) weld nut (part number N806285- S190).
2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327- S190).
3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back out an adjacent access hole.
4. Feed the copper welding wire through the weld nut, then through a standard flatwasher.
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5. Secure the flatwasher so that it cannot be pulled off the end of the copper welding wire.
6. Pull the copper welding wire back through the clearance hole, allowing the weld nut and
flatwasher to follow the copper welding wire through.
7. Position the weld nut to the weld nut clearance hole, firmly pulling on the copper welding wire allowing the secured flatwasher to hold the weld nut in position.
8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the edge of the weld nut.
9. Metal finish as required.
10. Verify the nut is securely in place.
11. Install the crash sensor.
12. Tighten the attaching screws to specification. For additional information, refer to Torque Specifications in this section. Klj . 2 ba
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GENERAL PROCEDURES
Weld Nut Repair —
Stripped Weld Nut, Restraints Control
Module (RCM)
WARNING: To avoid accidental deployment and possible personal injury, the backup
power supply must be depleted before repairing or replacing any front or side air bag
supplemental restraint system (SRS) components and before servicing, replacing, adjusting or
striking components near the front or side air bag sensors, such as doors, instrument panel,
console, door latches, strikers, seats and hood latches.
Please refer to the appropriate vehicle shop manual to determine location of the front air bag
sensors.
The side air bag sensors are located at or near the base of the B- pillar.
To deplete the backup power supply energy, disconnect the battery ground cable and wait at
least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455- S190).
2. Drill out the internal threads of the stripped- out weld nut to 7.37 mm (0.29 in) using a letter "L"
size drill bit.
3. Position the crash sensor to the vehicle.
4. Install the 8 mm (0.32 in) grounding screw into the drilled- out weld nut.
5. Install the remaining attaching screws.
6. Tighten the attaching screws to specification. For additional information, refer to Torque Specifications in this section.
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REMOVAL AND INSTALLATION
Restraints Control Module (RCM)
Removal
WARNING: The restraints control module (RCM) orientation is critical for proper system
operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) has been
involved in a collision in which the center tunnel area has been damaged, inspect the mounting
and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags
have deployed. In addition, make sure the area of the RCM mounting is restored to its original
condition.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle
equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect
the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position
the sensor or any other damaged supplemental restraint system (SRS) components whether or
not the air bag is deployed.
WARNING: The restraint system diagnostic tool is for restraint system service only.
Remove from vehicle prior to road use. Failure to remove could result in injury and possible
violation of vehicle safety standards.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to
these charges, damage can result.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Prepare the vehicle for restraints control module (RCM) removal. 1. WARNING: To avoid accidental deployment and possible personal injury, the
backup power supply must be depleted before repairing or replacing any front or
side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air
bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
Please refer to the appropriate vehicle shop manual to determine location of the
front air bag sensors.
The side air bag sensors are located at or near the base of the B- pillar. To deplete the backup power supply energy, disconnect the battery ground cable SECTION 501-
20B: Supplemental Restraint System 2003 Mustang Workshop Manual Special Tool(s)
Diagnostic Tool, Restraint
System (2 Req'd)
418-
F088 (105- R0012) Klj . 1 ba
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REMOVAL AND INSTALLATION
Driver Air Bag Module
Removal
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint
system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury
in the event of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from
your body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will
reduce the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium
hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your
hands with soap and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air
bag deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced,
not repainted.
WARNING: The restraint system diagnostic tool is for restraint system service only.
Remove from vehicle prior to road use. Failure to remove could result in injury and possible
violation of vehicle safety standards.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Prepare the vehicle for driver air bag module removal. 1. WARNING: To avoid accidental deployment and possible personal injury, the
backup power supply must be depleted before repairing or replacing any front or
side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air
bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches.
SECTION 501-
20B: Supplemental Restraint System 2003 Mustang Workshop Manual Special Tool(s)
Diagnostic Tool, Restraint
System (2 Req'd)
418-
F088 (105- R0012) Klj . 1 ba
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Please refer to the appropriate vehicle shop manual to determine location of the
front air bag sensors.
The side air bag sensors are located at or near the base of the B-
pillar.
To deplete the backup power supply energy, disconnect the battery ground cable
and wait at least one minute. Be sure to disconnect auxiliary batteries and power
supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to Section 414 - 01 .
2. WARNING: To reduce the risk of serious personal injury, read and follow all
warnings, cautions, notes, and instructions in the supplemental restraint system
(SRS) deactivation/reactivation procedure.
Deactivate the supplemental restraint system (SRS). For additional information, refer to
Supplemental Restraint System (SRS) Deactivation and Reactivation in the General
Procedures portion of this section.
2. Remove the two steering wheel plugs.
3. Remove the two driver air bag module retaining bolts (one shown).
4. Remove the driver air bag module. 1. Disconnect the driver air bag module electrical connector.
2. Remove the driver air bag module. Klj . 2 ba
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