It’s a buyer’s market for Ford’s final T-Bird… for now

Ford's two-seat, V-8 Thunderbird concept was a show-stopper on the 1999 car-show circuit. Created under the watchful eye of Ford design legend Jack Telnack, with details seen to by J Mays after Telnack's 1997 retirement, it was sporty without being a sports car, luxurious without costing an arm and a leg, elegant yet modern, and comfortable without being excessive. Some fuss was made about the 11th-generation Thunderbird's modern-retro style at the time: the eggcrate grille and driving light nacelles, the non-functional hood scoop, the round twin rear lights, the chromed script badging, the removable hardtop with the porthole, and the generous proportions with ample rear overhang. But these could easily just be seen as touchstones on an otherwise modern shape.

The production car's platform was shared with the Jaguar S-Type (and later, the Jaguar XF) sedan. The Thunderbird also shared its platform with the Lincoln LS sedan. Its much-heralded arrival as a 2002 model, with the first models built in 2001, ensured a 19-month initial production run and sales numbers that far outstripped Ford's 25,000-unit-per-annum estimate. More than 31,000 T-Birds, or 46 percent of all 2002-'05 T-Bird production, were '02s. For this reason, production can easily be broken into two groups: 2002s and the rest.

Ford updated the Thunderbird annually with special editions and exclusive paint colors. Torch Red and Evening Black are the only colors that lasted all four years. Whisper White was available in 2002-'03, Thunderbird Blue (an aqua metallic) in '02 only, and Inspiration Yellow was also an '02-only color. Mountain Shadow Grey and Desert Sky Blue were only for '03, as was Silver, Merlot, and Ice Blue were '04-only hues, while Monterey Mist was an exclusive for the Pacific Coast Roadster edition. Bronze, Medium Steel Blue, Cashmere, and Inca Gold only appeared in 2005. Of these, Inca Gold is the rarest of all T-Bird colors, with just 187 built.

Production ended in July 2005 with barely 68,000 built over four years. It wasn't a huge sales success in Ford's eyes, but the most recent Thunderbird still outsold the original two-seat T-Bird by 15,000 units and lasted a year longer. With the oldest of these cars coming up on two decades in age, it's still possible to find a clean, low-mileage example out there.

For this buyer's guide, we spoke to two people: Philip Wegener of Thunderbird Specialties, an online-based shop that deals exclusively with parts for the 2002-'05 Thunderbird, and Ken Berger of Phoenix, Arizona, a serial T-Bird buyer (nearly a dozen since his first new one in late '01) who owns our Torch Red '02 feature car. Between them, a clean picture of what to watch out for emerges.

Body

The body was unchanged during the T-Bird's four years of life, although a discreet V8 badge appeared on the fender behind the front wheel opening on '02 and '05 models only. Philip noted that "Doors and rear quarter panels are unavailable from Ford, although the front and rear bumper covers are still available through the dealer." The hood and trunk lid are both made of sheet-molded composite and are also not available from the dealer.

Philip suggests that the bulk of Thunderbird owners babied their cars, making plenty of good-quality, low-mileage examples readily available. Rust typically isn't an issue: He's found that "most put their Thunderbirds in hibernation from October to April."

Something to note is the boot that covers the folded soft roof. "The '02 soft boot took up most of the trunk," Ken said. "In '03, Ford went with a different padded multipiece design that could be folded and stored. I think it's an improvement. And the snap configuration is the same—any boot will fit any year."

Also, the optional hardtop can leave rub marks between the trunk lid and the soft-top well. "Any hardtop is going to do that," Ken said. "The factory put the tops on when paint was still fresh." The factory offered a hardtop protection kit consisting of mylar strips, gel, and an applicator. Thunderbird Specialties still has a few sets in stock, though it has developed a stainless- steel protection strip said to prevent scratches and reduce rattles and squeaks in the hardtop.

Electronics

One of the things that scares collectors about modern cars is the cost and complexity of fixing various computer systems. "The one that fails most is the FEM, or Front Electronic Module, lighting," Philip said. "I must get five calls a day from people who need an FEM, but Ford obsoleted it in 2018. There are also the PCM, or powertrain control module, and REM, the rear electronic module." What's more, each module is vehicle-specific—you can't just plug one in you scrounged at a boneyard and make everything right again. Because of this demand, Philip reached out to Ford, and prevailed upon it to do something. Ford did: Through Thunderbird Specialties, and not through standard channels like your local dealer's parts department, Ford will remanufacture the FEM. "There's a high core charge, and you need lots of information— the part number, your car's engineering number, the odometer reading, the VIN, the owner's name, and the old core."

Two-seat T-Bird shows off its sporting optional "partial interior color accent" interior on the steering wheel, shifter, instrument panel, door panel, and seats. Not all shades were available as interior accent colors.

Interior/Top

Small but significant interior differences separate the 2002 and the 2003-'05 models. The 2002 gauge cluster was unique, with the gauge faces arranged to appear as if they overlap. The 2003-'05 gauges are their own individual semi-circles. The 2002 has a hook on the glovebox latch (presumably for a trash bag); it disappeared in '03 and never returned. The '02 model has vinyl sun visors, while the 2003-'05 has cloth. Subtle differences in material and color can help identify one year from another. Optional complementary body-colored interior trim was available with some colors.

"Rattles and squeaks from the hardtop generally come from improper attachment," said Philip. "There are two clamps in back and two bolts in the header; if it's not done in sequence" then noise can crop up. All years of hardtop will fit any 2002-'05 T-Bird, regardless of whether it was equipped with one at the factory or not. Hardtop-equipped models came with a folding hardtop rack for storage when not in use.

The optional removable hardtop (with 1956-'57-style porthole window) takes two people to remove; many owners simply leave it on the car and keep the rack folded up out of sight. Most hardtops were painted body color, though some special versions had contrasting tops.

The convertible soft-top latches have plastic bushings that deteriorate and crack, releasing a spring, and the pivot arm can also break. This is "in the top five of overall issues with the Thunderbird," Philip said. "Repair kits are available from Ford. It sells an entire clamp assembly; Thunderbird Specialties sells individual components." And watch for a worn or weather-beaten convertible top as well.

Other issues include a six-CD changer that will neither return nor play your music (occasionally fixable by disconnecting the battery and letting the electronics reset; otherwise the unit needs to be opened and re-lubricated), seat leather than can crack or fade, and the inner door handles. "They work fine, but the chrome peels. Little stuff like that is annoying," Kenny said. According to Philip, "Inner door handles are increasingly difficult to find; the handle is riveted to the latch assembly and was never available separately. Disassembling and rechroming it is expensive, and with a used handle, you're replacing one 15-yearold part with another."

For 2002, the 3.9-liter DOHC V-8 put out 252 horsepower; for 2003-'05 models, variable valve timing on the intake cams helped bump power to a respectable 280 horses. The sunken-in hood scoop is nonfunctional.

Engine

The Thunderbird's 32-valve DOHC V-8 displaced 3.9 liters (242-cu.in.), and despite the Jaguar architecture was a unique variant built in Lima, Ohio. The AJ30's block, crank, pistons, and fracture-split, forged-powder-metal connecting rods are all unique to this engine and are not shared with Jaguar. The 2002 version offered 252 horsepower at 6,100 rpm, and 267 lb-ft of torque at 4,300 rpm. For 2003, the updated AJ35 variant added electronic throttle control, variable timing on the intake camshafts, and an electric cooling pump (replacing a hydraulic unit) for reduced drag. Power was bumped to 280 horsepower at 6,000 rpm. The AJ35 ceased production in 2006, with more than a quarter-million built; AJ-architecture engines will cease production in September.

The biggest issue with Thunderbird engines is with the coil-on-plug ignition. Philip said, "I've heard from people with high-mileage cars who haven't had issues, and I've seen them go bad on cars from 20,000 to 70,000 miles. Motorcraft makes a correct replacement and, at $75-$90 each, they're not expensive, but labor is. And once one coil fails, the others won't be far behind, so you should do at least one bank of the V-8 at a time, if not all at once." Ken says that part of the problem is that "the valve covers leak, and oil fills the valley where the coil packs are and shorts them out. It's not a hard fix, but it's annoying. If you keep them dry, and if the gaskets are good, they'll go forever."

Transmission and Axle

The transmission is Ford's 5R55E, an electronically-controlled five-speed automatic transmission. All 2002s and standard 2003-'05 models have a PRNDL shifter. Starting in 2003, the optional SelectShift (manumatic) shift pattern appeared.

"The transmissions don't get beat up much—the engine doesn't overpower them, which helps," said Philip. "The transmission is sealed—you can't even check the fluid level from under the hood. Most transmission issues, I have found, are caused by opening the system and creating problems that didn't exist before that. Oil change shops often underfill or overfill. Ford recommends just leaving it alone."

Brakes and Suspension

All of Thunderbird's factory wheels were 17 x 7.5, fitted with P235/50R17 95V Michelin Pilots. It's a common enough tire size, although some owners move up to a 55-series for a little more sidewall and ride comfort. The 2002-'03 has two available wheels: a painted silver 21-spoke or a chromed seven-spoke (the special Neiman Marcus and 007 editions got chromed versions of the painted wheel). The 2004-'05 models had a refreshed wheel selection.

The one tire to check on, though, is the spare. "The donut spare can blow up in the trunk from age," said Ken. "You gotta get it out. One day you hear a 'boom!' and you have a trunk full of rubber dust." Philip explains further: "They get dry-rotted over the years, and most owners never look at it. At 60 psi, it can explode and tear up the liner and panels of the trunk. And even if it's intact, if you put a load on it, it probably won't hold up. The 2002 spares were made by Firestone; they switched to another company after 2002. It's a special- order piece from a tire shop since most dealers and shops don't carry them, and should be less than $300."

The four-wheel independent suspension is very robust, Philip claims. Your local Ford parts counter and local parts store should have all of the other components needed to keep a 'Bird feeling fresh. Watch the bushings, however: They're hard nylon and can crack with age. Some Lincoln LS suspension parts are compatible with the T-Bird, none from the S-Type Jaguar are— despite riding on the same platform.

WHAT TO PAY

PARTS PRICES

Climate control sensor $99

Coil spring $349

Convertible soft-top $1,699

Front bumper cover $995-$1,495

Front marker light $70

Fuel tank $899

Grille (chrome-plated) $388

Hood scoop $299

Hood support struts $129

Inner door handle assembly $589

Quarter molding $399

Rear shock assembly $162

Trunk liner $229

Valve cover $295

"V8" emblem $60

Wheel center caps $199

Wings trunk emblem $99

PHOTOGRAPHY BY JEFF KOCH