This bulletin supersedes 24-2002. Reason for update: update the symptom, production fix date and the Service Procedure

Model:

Markets: Canada, USA

Issue: Some 2021-2024 Mustang Mach-E vehicles built on or before 09-Jul-2024 may exhibit a wind noise from the exterior mirrors/A-pillar area when driving between 25 mph-40 mph (32 km/h-64 Km/h). This may be due to poor sealing of the lower mirror foam and the glass top run foam. To correct this condition, follow the Service Procedure to install new lower inner foam and the glass top run foam.

NOTE: A small amount of wind noise from around the exterior mirrors is considered to be characteristic of vehicle design.

Action: Follow the Service Procedure to correct the condition on vehicles that meet all of the following criteria:

• 2021-2024 Mustang Mach-E

• Built on or before 09-Jul-2024

• Wind noise from exterior mirrors/A-pillar area when driving between 25 mph-40 mph (32 km/h-64 km/h)

Parts

Parts - Parts Only Applicable To Vehicles Built On or Before 06-Nov-2023

Claim Quantity refers to the total number of individual pieces required to repair the vehicle.

Package Order Quantity refers to the amount of the service part number package(s) required to repair the vehicle.

Number In Package refers to the number of individual pieces included in a service part number package.

Warranty Status: Eligible under provisions of New Vehicle Limited Warranty (NVLW)/Service Part Warranty (SPW)/Service Part New Vehicle (SPNV)/Extended Service Plan (ESP) coverage. Limits/policies/prior approvals are not altered by a TSB. NVLW/SPW/SPNV/ESP coverage limits are determined by the identified causal part and verified using the OASIS part coverage tool.

Labor Times

Repair/Claim Coding

Service Procedure

1. Perform a road test to identify if the wind noise is coming from the exterior mirrors/A-pillar. Does the vehicle exhibit a wind noise coming from one or both exterior mirrors?

(1). Yes - proceed to Step 2.

(2). No - this article does not apply. Perform normal diagnostics. Refer to WSM, Section 100-04.

2. Lower the front door window glass of the affected side to the fully down position.

3. Remove the exterior mirror. Refer to WSM, Section 501-09 Rear View Mirrors > Removal and Installation > Exterior Mirror Assembly.

4. If the exterior mirror foam gasket/seal remains on the door, remove and refit the mirror foam gasket/seal back onto the mirror before reassembly. (Figure 1)

Figure 1

5. Separate and fold back the front door glass top run from the door frame and the run channel in the areas highlighted in Figure 2.

Figure 2

6. Is the vehicle built on or before 06-Nov-2023?

(1). Yes - proceed to Step 7.

(2). No - proceed to Step 9.

7. Remove the existing lower inner foam.

8. Install the new lower inner foam.

(1). Insert the front of the foam first making sure is seated under the window run/sheet metal and the foam shape properly fits the curves of the door. (Figure 3)

Figure 3

(2). Evenly tuck all edges of the foam into the door making sure that the rear sections sit flush against the window run frame with no gaps. (Figure 4)

Figure 4

9. Print the foam template by clicking this link. Verify the horizontal and vertical scale of the image using a ruler against the scale on the template printout (Figure 5) to confirm the image scale is correct. Is the scaling of the template printout the same scale as the ruler?

Figure 5

(1). Yes - proceed to Step 10.

(2). No - adjust scale of the printing properties to actual size to resize the image. Repeat Step 9.

10. Layer together 3 pieces of the PVC Soft Foam Strips to obtain the desired thickness.

11. Cut the shapes from the template printed out and trace the shape of the back side of the foam. Cut the foam along the line traced on the back to create the shape indicated in Figure 6.

Figure 6

12. Cut an additional 10 mm (0.39 in.) slice into the foam in the area indicated in Figure 7.

Figure 7

13. Remove the existing glass top run foam and clean the surface to remove any residual foam. (Figure 8-9)

Figure 8

Figure 9

CAUTION: Be careful to not tear the rubber of the glass top run when fitting/tucking the foam underneath.

14. Install the cut pieces of foam onto the glass top run.

(1). Align the foam with the ridge along A-pillar and the lip along the header. (Figure 10)

Figure 10

(2). Apply pressure to adhere the foam to the inner surface of the glass top run. (Figure 11)

Figure 11

(3). Fold and pressurize the lower area of the foam over the back of the A-pillar channel, leaving the upper extension unadhered. (Figure 12)

Figure 12

(4). Moving to the exterior of the glass top run, take the end of the foam extension and pull, seating the foam toward the header/A-pillar corner. (Figure 13)

Figure 13

(5). Tuck the end of the foam extension high up under the lip of the glass top run following the upward angle of the run. (Figure 14)

Figure 14

15. Reinstall the front door glass top run in the door frame and the run channel. (Figure 15)

Figure 15

16. Reinstall the exterior mirror. Refer to WSM, Section 501-09 Rear View Mirrors > Removal and Installation > Exterior Mirror Assembly.

NOTE: A small amount of wind noise from around the exterior mirrors is considered to be characteristic of vehicle design.

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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 or Lincoln 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 supersede this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.