Mustang V8-4.6L VIN H (2005)
Marker Lamp: Customer Interest
Lighting - Front Marker Light Retainer Tab Breakage
TSB 05-15-13
08/08/05
FRONT SIDE MARKER LAMP RETAINING TAB BREAKING
FORD:
2005 Mustang
ISSUE
Some 2005 Mustang vehicles may exhibit a concern with the front side marker lamp retainer tab breaking in the bumper cover, due to an impact.
ACTION
It may be necessary to repair the side marker lamp retainer tab. Refer to the following Service Procedure.
SERVICE PROCEDURE
INSPECTION PROCEDURE
1.
Remove the front bumper cover and the side marker lamps. Refer to Workshop Manual Section 501-19.
2.
Inspect the bumper cover for external cracks, broken reinforcements or broken attachment tabs.
3.
Inspect the bumper cover for broken or missing side marker lamp retainer tabs.
Feasibility of repairing the bumper should include the following considerations:
^
Can the bumper cover be repaired to a customer acceptable level of quality of appearance, fit, and durability
^
Will the labor and material cost of the repair meet or exceed the cost of a new replacement bumper cover
If the bumper cover is determined to be repairable, refer to one of the following repair procedures for the repair material brand you will use.
SIDE MARKER RETAINER TAB REPAIR PROCEDURE USING FUSOR BRAND MATERIALS
1.
Clean the broken tab with wax and grease remover.
2.
Hand sand the repair area with 80 grit sandpaper, and remove any debris with compressed air.
3.
Apply Fusor Surface Modifier (602) to the repair area, and let it dry for 10-15 minutes.
4.
Measure and cut a patch of Fusor Plastic Fiberglass Cloth (702) large enough to form the front of the tab, then slope back in a wedge shape
approximately 2" (51 mm) from original lamp retainer tab.
a.
If the original lamp retainer tab is completely missing, the opening for the new tab wedge may be fabricated using mild steel wire formed in
a channel shape.
5.
Prepare the Fusor Plastic Repair Adhesive (143) (5U7Z-19B508-A) per manufacturer's instructions and apply in the form of the wedge outlined
earlier, while inserting the tab opening metal reinforcement fabricated in step 4a if needed.
6.
Immediately apply the fiberglass cloth into the plastic repair adhesive for reinforcement, apply more plastic repair adhesive for shape and strength
as required.
7.
Allow 20 minutes to cure. Shape the repair wedge using a small angle sander. Use extreme care to not sand through to the exterior surface.
8.
Using a die grinder with a small round cutting bit, shape the opening for the light tab in the repair wedge. Work carefully to not cut through the
exterior. Trial fit the light to determine proper engagement.
9.
Perform any needed paint repair operations to the bumper cover using Ford approved paint systems.
10.
Reassemble the lights and the completed bumper cover to the vehicle.
SIDE MARKER RETAINER TAB REPAIR PROCEDURE USING 3M BRAND MATERIALS