Lincoln Corsair Manuals

Lincoln Corsair: Body System - General Information / Diagnosis and Testing - Body System

Global Customer Symptom Code (GCSC) Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).


Symptom Action
Fit/Finish/Body > Water Leak > Passenger Area > Appearance GO to Pinpoint Test A
Fit/Finish/Body > Water Leak > Passenger Area > Appearance GO to Pinpoint Test B
Fit/Finish/Body > Water Leak > Passenger Area > Appearance GO to Pinpoint Test H
Fit/Finish/Body > Water Leak > Cargo/Bed Area > Appearance GO to Pinpoint Test F
Fit/Finish/Body > Water Leak > Cargo/Bed Area > Appearance GO to Pinpoint Test K
Fit/Finish/Body > Water Leak > Cargo/Bed Area > Appearance GO to Pinpoint Test L
Fit/Finish/Body > Noise > Instrument Panel > Always GO to Pinpoint Test G
Fit/Finish/Body > Noise > Floor > Always GO to Pinpoint Test F
Fit/Finish/Body > Noise > Door > Always GO to Pinpoint Test G
Fit/Finish/Body > Noise > Wind > Always GO to Pinpoint Test C
Fit/Finish/Body > Noise > Wind > Always GO to Pinpoint Test D
Fit/Finish/Body > Noise > Wind > Always GO to Pinpoint Test E
Fit/Finish/Body > Noise > Wind > Always GO to Pinpoint Test I
Fit/Finish/Body > Noise > Wind > Always GO to Pinpoint Test K
Fit/Finish/Body > Noise > Wind > Always GO to Pinpoint Test L
Fit/Finish/Body > Noise > Wind > Always GO to Pinpoint Test M
Fit/Finish/Body > Noise > Wind > Always GO to Pinpoint Test N
Fit/Finish/Body > Noise > Wind > Always GO to Pinpoint Test O
Fit/Finish/Body > Noise > Wind > Always GO to Pinpoint Test P
Fit/Finish/Body > Noise > Wind > Always GO to Pinpoint Test Q
Lighting/Glass/Vision > Mirror > Side > Loose/Attachment GO to Pinpoint Test I
Lighting/Glass/Vision > Mirror > Side > Loose/Attachment GO to Pinpoint Test J

Symptom Chart(s)

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).

Dust and Water Leaks

Most dust and water leaks occur due to missing or incorrectly installed body sealer or components. The source of the leak is detected by:

  • pressurizing the vehicle and testing with soapy water.
    • Locate and tape off the body vents.
    • Turn the blower motor to HI.
    • Turn the air recirculation OFF.
    • Close the windows and doors.
    • Open the hood and spray soapy water along body seams and grommets. Make sure to test the areas around the A-pillar at the fender and the hood hinge area.
    • Check for bubbles.
  • inspecting for a dust pattern or water path near and above the area in question.
  • removing any trim or carpet in the general area of the leak.
  • road testing or water-hose testing the vehicle.
  • placing a bright light under the vehicle, removing any necessary trim or carpet and inspecting the interior of the body at joints and weld lines.

Wind noise

Most wind noise leaks occur at the corners of the windows or in the doors. Wind noise is detected by driving the vehicle at highway speeds or at speeds as specified by the customer. The vehicle should be driven in 4 different directions, with all the windows closed, the radio off and the A/C blower motor off.

Squeak and Rattle

Squeak and rattle noises are generally caused by loose parts, contact or relative movement between 2 surfaces or loose wires and connectors. The source of the noise can be detected by stopping movement of the suspect part by hand or by using dampening or low friction materials.

Symptom Chart: Body System - General Information


Condition Actions
Draft/wind noise and water leak around door perimeter   GO to Pinpoint Test A
Draft/wind noise and water leak around glass run   GO to Pinpoint Test B
Draft/wind noise and water leak at inner belt line   GO to Pinpoint Test C
Draft/wind noise and water leak at outer belt line   GO to Pinpoint Test D
Draft/wind noise at inner door handle/speaker opening   GO to Pinpoint Test E
Road noise and leaks at floor pan and grommets   GO to Pinpoint Test F
Rattles in body/doors and instrument panel   GO to Pinpoint Test G
Door drain holes collecting water   GO to Pinpoint Test H
Wind noise from exterior rear view mirror   GO to Pinpoint Test I
Rattle/vibration from exterior rear view mirror   GO to Pinpoint Test J
Draft/wind noise and water leak around perimeter of all fixed glass   GO to Pinpoint Test K
Draft/wind noise and water leak around liftgate/luggage compartment perimeter   GO to Pinpoint Test L
Wind noise created by airflow over or behind body panels   GO to Pinpoint Test M
Wind noise created by grille opening panel   GO to Pinpoint Test N
Wind noise from air extractor (body vent)   GO to Pinpoint Test O
Wind noise from bug shield/exterior windshield sun visor   GO to Pinpoint Test P
Wind noise from cowl panel (leaf screen)   GO to Pinpoint Test Q

Pinpoint Tests


PINPOINT TEST A: WATER LEAK AROUND DOOR PERIMETER

Normal Operation and Fault Conditions

REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Seal
  • Scuff plate
  • Sheet metal joints
  • Door alignment
A1 CHECK SEAL INSTALLATION
  • Check seal for the following
    • Loose fit
    • Incorrect installation
    • Damaged seal pushpins

Was any concern found?
Yes Resolve the concern and reinstall the seal correctly.
No GO to A2

A2 CHECK SCUFF PLATE INSTALLATION
  • Check scuff plate installation

Is the scuff plate installed incorrectly?
Yes Remove and reinstall the scuff plate correctly.
No GO to A3

A3 CHECK SHEET METAL JOINTS
  • Check sheet metal joints

Are sheet metal joints leaking?
Yes Seal sheet metal joints with seam sealer.
No GO to A4

A4 CHECK DOOR ALIGNMENT
  • Check door alignment.

Are door aligned incorrectly?
Yes Refer door alignment procedure. REFER to: Front Door Alignment (501-03 Body Closures, General Procedures).
REFER to: Rear Door Alignment (501-03 Body Closures, General Procedures).
No The system is operating correctly at this time. Inspect the vehicle for other symptoms.

PINPOINT TEST B: WATER LEAK AROUND GLASS RUN

Normal Operation and Fault Conditions

REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Glass run
  • Door applique
B1 CHECK GLASS RUN INSTALLATION
  • Check installed glass run seal for the following
    • Loose fit
    • Incorrect installation
    • Glass run overstuffed in corners
    • Glass run reveal lip not contacting sheet metal

Was any concern found?
Yes Remove and reinstall the glass run correctly.
No GO to B2

B2 CHECK GLASS RUN CHANNEL
  • Check whether glass run channel is deformed or spread wide

Was any concern found?
Yes Pinch the glass run channel to reduce size of opening.
No GO to B3

B3 CHECK FOR MISALIGNED DOOR APPLIQUE
  • Check whether the door applique is correctly installed.

Is the door applique misaligned and causing glass run to twist?
Yes Remove and reinstall the door applique to ensure the glass run is seated correctly. Replace components as necessary.
No GO to B4

B4 CHECK FOR DAMAGED GLASS RUN
  • Check whether the glass run is damaged.

Was any concern found?
Yes Replace the glass run.
No The system is operating correctly at this time. Inspect the vehicle for other symptoms.

PINPOINT TEST C: DRAFT/WIND NOISE AT INNER BELT LINE

Normal Operation and Fault Conditions

REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Inner belt line seal
C1 CHECK BELT LINE SEAL INSTALLATION
  • Check belt line seal installation for the following
    • Incorrect installation
    • Contact with glass run
    • Contact with window glass

Was any concern found?
Yes Adjust the belt line seal and the window glass. Install foam at seal ends if required.
No GO to C2

C2 CHECK BELT LINE SEAL FOR DAMAGE
  • Check condition of belt line seal.

Was any concern found?
Yes Replace the belt line seal.
No The system is operating correctly at this time. Inspect the vehicle for other symptoms.

PINPOINT TEST D: DRAFT/WIND NOISE AT OUTER BELT LINE

Normal Operation and Fault Conditions

REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Outer belt line seal
D1 CHECK BELT LINE SEAL INSTALLATION
  • Check belt line seal installation for the following
    • Incorrect installation
    • Contact with glass run
    • Contact with window glass

Was any concern found?
Yes Adjust the belt line seal and the window glass. Install foam at seal ends if required.
No GO to D2

D2 CHECK BELT LINE SEAL FOR DAMAGE
  • Check condition of belt line seal

Was any concern found?
Yes Replace the belt line seal.
No The system is operating correctly at this time. Inspect the vehicle for other symptoms.

PINPOINT TEST E: DRAFT/WIND NOISE AT INNER DOOR HANDLE/SPEAKER OPENING

Normal Operation and Fault Conditions

REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Misaligned/damaged weathershield
  • Misaligned/damaged door handle seal
  • Misaligned/damaged door speaker seal
E1 CHECK THE WEATHERSHIELD
  • Check weathershield installation for the following;
    • Misaligned/Incorrect installation
    • Damage or cuts

Was any concern found?
Yes Align the weathershield correctly. Replace the weathershield if necessary.
No GO to E2

E2 CHECK THE DOOR HANDLE SEAL
  • Check the door handle seal installation for the following;
    • Misaligned/incorrect installation
    • Damage or cuts

Was any concern found?
Yes Adjust the door handle seal correctly. Replace the door handle seal if necessary
No GO to E3

E3 CHECK THE DOOR SPEAKER SEAL
  • Check the door speaker installation for the following;
    • Missing door speaker
    • Damaged door speaker

Was any concern found?
Yes Repair the door speaker seal. If required, replace the door speaker.
No The system is operating correctly at this time. Check the vehicle for other symptoms.

PINPOINT TEST F: ROAD NOISE AND LEAKS AT FLOOR PAN AND GROMMETS

Normal Operation and Fault Conditions

REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Plugs or grommets
  • Mastic insulator or body insulators
F1 CHECK FOR MISSING, DAMAGED OR INCORRECTLY INSTALLED PLUGS OR GROMMETS
  • Check for missing, damaged or incorrectly installed plugs or grommets.

Was any concern found?
Yes Remove and reinstall the plugs/grommets correctly. Replace components as necessary.
No GO to F2

F2 CHECK FOR MISSING MASTIC INSULATORS OR BODY INSULATORS
  • Check for missing mastic or body insulators.

Are the mastic or body insulators missing?
Yes Replace the mastic or body insulators.
No The system is operating correctly at this time. Inspect the vehicle for other symptoms.

PINPOINT TEST G: RATTLES IN BODY/DOORS AND INSTRUMENT PANEL

Normal Operation and Fault Conditions

REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Loose wires/cables
  • Loose components
G1 CHECK FOR LOOSE WIRES/CABLES
  • Check whether all wires/cables are correctly installed.

Are there any loose wires/cables?
Yes Correctly route and install all wires/cables using retainers.
No GO to G2

G2 CHECK FOR LOOSE COMPONENTS IN DOOR WELLS AND QUARTER TRIM PANELS
  • Check for loose objects and components inside door wells and quarter trim panels.

Are there any loose objects or components found?
Yes Remove or tighten the loose objects and components.
No GO to G3

G3 CHECK FOR BUZZING SOUND FROM INSTRUMENT PANEL COMPONENTS
  • Check for buzzing sound from instrument panel components.

Was any concern found?
Yes Secure and fasten the components as necessary. Use foam or felt to eliminate the noise.
No The system is operating correctly at this time. Inspect the vehicle for other symptoms.

PINPOINT TEST H: WATER COLLECTING IN DOORS

Normal Operation and Fault Conditions

REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Clogged door drains
H1 CHECK FOR CLOGGED DOOR DRAINS
  • Check whether door drains are clogged with foreign material.

Are door drains blocked or clogged?
Yes Using a punch or screwdriver, remove the blockage.
No The system is operating correctly at this time. Inspect the vehicle for other symptoms.

PINPOINT TEST I: WIND NOISE FROM EXTERIOR REAR VIEW MIRROR

Normal Operation and Fault Conditions

REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Exterior rear view mirror misalignment
  • Folded or misaligned mirror sail gasket
  • Mirror housing trim caps for incorrect installation
I1 CHECK EXTERIOR REAR VIEW MIRROR MISALIGNMENT
  • Check whether the exterior rear view mirror is misaligned.

Was any concern found?
Yes Remove and reinstall the exterior rear view mirror. Realign the edges and make sure there are no gaps.
No GO to I2

I2 CHECK FOR FOLDED OR MISALIGNED MIRROR SAIL GASKET
  • Check for folded or misaligned mirror sail gasket.

Is the mirror sail gasket folded or misaligned?
Yes Reinstall the gasket unfolded and aligned correctly.
No GO to I3

I3 CHECK MIRROR HOUSING TRIM CAPS FOR INCORRECT INSTALLATION
  • Check mirror housing trim caps for incorrect installation

Was any concern found?
Yes Remove and reinstall the mirror housing trims correctly.
No The system is operating correctly at this time. Inspect the vehicle for other symptoms.

PINPOINT TEST J: RATTLE/VIBRATION FROM EXTERIOR REAR VIEW MIRROR

Normal Operation and Fault Conditions

REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Loose exterior rear view mirror mounting bolts
  • Broken exterior rear view mirror components
  • Aftermarket components installed on the vehicle
J1 CHECK FOR LOOSE EXTERIOR REAR VIEW MIRROR MOUNTING BOLTS
  • Check for loose exterior rear view mirror mounting bolts.

Are the exterior rear view mirror mounting bolts loose?
Yes Tighten the exterior rear view mirror mounting bolts.
No GO to J2

J2 CHECK FOR BROKEN EXTERIOR REAR VIEW MIRROR COMPONENTS
  • Check for broken exterior rear view mirror components.

Are the exterior rear view mirror mounting components broken?
Yes Replace the broken exterior rear view mirror mounting components as required.
No GO to J3

J3 CHECK FOR AFTERMARKET COMPONENTS INSTALLED ON THE VEHICLE
  • Check aftermarket components installed on the vehicle

Are there any aftermarket components installed?
Yes Ford recommends using genuine Ford approved components to be installed on vehicle. Check vehicle for noise without the aftermarket components if possible.
No The system is operating correctly at this time. Inspect the vehicle for other symptoms.

PINPOINT TEST K: DRAFT/WIND NOISE AND WATER LEAK AROUND PERIMETER OF ALL FIXED GLASS

Normal Operation and Fault Conditions

REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Missing seals
  • Incorrect installation
K1 CHECK THE A-PILLER MOLDING
  • Check the A-piller molding installation for the following;
    • Misaligned/incorrect installation
    • Loose fit
    • Missing foam seal

Was any concern found?
Yes Reinstall the A-piller molding. Install a foam rope full length of the A-piller.
No GO to K2

K2 CHECK THE WINDSHIELD/REAR WINDOW GLASS INSTALLATION
  • Check the windshield/rear window glass installation for the following;
    • Gaps in the sealant bead
    • Misalignment

Was any concern found?
Yes Install new windshield/rear glass.
REFER to: Fixed Glass (501-11 Glass, Frames and Mechanisms, General Procedures).
No GO to K3

K3 CHECK THE SEALS
  • Check the rear hood seal at the base of the windshield of the following;
    • Misalignment
    • Damage

Was any concern found?
Yes Arealign or install a new seal as necessary.
No GO to K4

K4 CHECK THE HIGHMOUNTED STOPLAMP
  • Check the high mounted stoplamp for the following;
    • Loose fit
    • Missing seal
    • Damage

Was any concern found?
Yes Check the installation of the high mounted stoplamp. Check the seal. Repair or install the high mounted stoplamp as necessary.
No The system is operating correctly at this time. Check the vehicle for other symptoms.

PINPOINT TEST L: DRAFT/WIND NOISE AND WATER LEAK AROUND LIFTGATE/LUGGAGE COMPARTMENT PERIMETER

Normal Operation and Fault Conditions

REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Misaligned/damaged/loose seals
  • Misaligned liftgate/luggage compartment
  • Misaligned scuff plate
L1 CHECK SEAL INSTALLATION FOR DAMAGED OR IMPROPER INSTALLATON
  • Check the liftgate/luggage compartment pinch seal for the following;
    • Misaligned/incorrect installation
    • Damage or Cut
    • Loose fit
    • Damged seal pushpins

Was any concern found?
Yes Reinstall the seal. Install new seal or pushpins as neccessary.
No GO to L2

L2 CHECK THE SCUFF PLATE
  • Check the scuff plate for loose or improper installation.

Was any concern found?
Yes Reinstall the scuff plate. Install a new scuff plate as necessory.
No The system is operating correctly at this time. Check the vehicle for other symptoms.

L3 CHECK THE LIFTGATE/LUGGAGE COMPARTMENT DOOR ALIGNMENT
  • Check the liftgate/luggage compartment door alignment.

Was any concern found?
Yes Perform a liftgate/luggage compartment door alignment.
REFER to: Liftgate Alignment (501-03 Body Closures, General Procedures).
No The system is operating correctly at this time. Check the vehicle for other symptoms.

PINPOINT TEST M: WIND NOISE CREATED BY AIRFLOW OVER OR BEHIND BODY PANELS

Normal Operation and Fault Conditions

REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Body panel misalignment
  • Aftermarket components installed on the vehicle
M1 CHECK BODY PANEL MISALIGNMENT
  • Check whether all body panels are aligned correctly.

Are any body panels found misaligned?
Yes Realign the appropriate body panel and test the vehicle again.
No GO to M2

M2 CHECK FOR AFTERMARKET COMPONENTS INSTALLED ON THE VEHICLE
  • Check aftermarket components installed on the vehicle

Are there any aftermarket components installed?
Yes Ford recommends using genuine Ford approved components to be installed on vehicle. Check vehicle for noise without the aftermarket components if possible.
No GO to M3

M3 CHECK WIND NOISE AT HIGHWAY SPEEDS
  • Check wind noise at highway speeds.
  • Replicate the wind noise by driving vehicle in all four directions under the following conditions
    • All windows closed
    • Turn radio OFF
    • A/C blower motor OFF

Was the wind noise replicated?
Yes Identify the location of the wind noise and make necessary repairs.
No The system is operating correctly at this time. Inspect the vehicle for other symptoms.

PINPOINT TEST N: WIND NOISE CREATED BY GRILLE OPENING PANEL

Normal Operation and Fault Conditions

REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Incorrect installation
  • Component imperfections
  • Damaged components
  • Loose components
N1 CHECK THE GRILLE OPENING PANEL INSTALLATION
  • Check the grille opening panel installation for the following;
    • Misaligned/Incorrect installation
    • Grille opening panel fit to the leading edge of the hood

Was any concern found?
Yes Adjust the grille opening panel forward to eliminate wind noise.
No GO to N2

N2 CHECK FOR COMPONENT IMPERFECTIONS
  • Check wheather the grille opening panel has imperfections such as sharp edge or foreign material attached to the grille opening panel.

Was any concern found?
Yes Remove the sharp edges. Clean the grille opening panel for any deposits of foreign material.
No GO to N3

N3 CHECK FOR DAMAGED GRILLE OPENING PANEL
  • Check weather the grille opening panel is damaged.

Was any concern found?
Yes Replace the grille opening panel.
No The system is operating correctly at this time. Check the vehicle for other symptoms.

PINPOINT TEST O: WIND NOISE FROM AIR EXTRACTOR (BODY VENT)

Normal Operation and Fault Conditions

\REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Incorrect installation
  • Damaged components
O1 CHECK THE AIR EXTRACTOR HOUSING INSTALLATION
  • Check the air extrator housing installation for the following;
    • Misaligned/Incorrect installation

Was any concern found?
Yes REINSTALL the air extractor housing.
No GO to O2

O2 CHECK THE AIR EXTRACTOR HOUSING FOR DAMAGE
  • Check the air extrator housing installation for the following;
    • Housing damage
    • Damaged flaps

Was any concern found?
Yes Install a new air extractor.
No The system is operating correctly at this time. Check the vehicle for other symptoms.

PINPOINT TEST P: WIND NOISE FROM BUG SHIELD/EXTERIOR WINSHIELD SUN VISOR

Normal Operation and Fault Conditions

REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Incorrect installation
  • Aftermarket accessories
P1 CHECK FOR AFTERMARKET INSTALLATION
  • Check for any aftermarket installed accessories on the vehicle

Are any aftermarket accessories found?
Yes Advise the customer about aftermarket installed accessories on the vehicle. Ford recommends use or approved accessories on the vehicle.
No GO to P2

P2 CHECK FOR INCORRECT INSTALLATION OR DAMAGE
  • Check the bug shield/exterior windshield sun visor for incorrect installation or damage.

Was any concern found?
Yes Reinstall the component to resolve the concern. Replace the component as necessory.
No The system is operating correctly at this time. Check the vehicle for other symptoms.

PINPOINT TEST Q: WIND NOISE FROM COWL PANEL (LEAF SCREEN)

Normal Operation and Fault Conditions

REFER to: Body - Overview (501-00 Body System - General Information, Description and Operation).

Possible Sources

  • Cowl panel grille rubber lip
Q1 CHECK LEAF SCREEN RUBBER LIP INSTALLATION
  • Check weather the LEAF SCREEN RUBBER LIP is installed correctly or damaged.

Was any concern found?
Yes REINSTALL the part. Check for damaged attachment clips. Install new part as neccesary.
No The system is operating correctly at this time. Check the vehicle for other symptoms.


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