The Real Reason You Can’t Find Parts for your T-Bird.
The answer may surprise you. You take your 2002-2005 Thunderbird to your Ford dealer for what seems like a simple repair, only to be told that it will take weeks to find a needed part. Sound Familiar? Almost every owner of a 2002-2005 Thunderbird has experienced the frustration of searching for or waiting for a needed repair or replacement part only to discover it’s not available. OEM replacement parts for many, older cars seem to be readily available, so why is it so hard to find replacement parts for the new Thunderbird? And why are the few remaining parts so expensive?
The answer may surprise you.
Every Retro owner knows that their cars are now between 10-13 years old and that older cars require more repairs as they age. But finding Ford factory OEM replacement parts or even aftermarket replacement parts seems to be more difficult for the 2002-2005 Thunderbird than other comparable cars its age. Even seemingly common parts and accessories like OEM floor mats and shocks & struts have disappeared. How can this happen for a modern American-made car less than 15 years old?
One reason is the rather small production numbers for the 2002-2005 Thunderbird. With just 68,095 produced for the four model years, it falls into the category of ‘niche’ vehicles, appealing to a limited potential target market. Let’s face it, a two-seat convertible roadster is not the most practical vehicle for a family. By contrast, Ford manufactured almost 200,000 Mustangs for the 2005 model year alone! Nearly three times the number of Thunderbirds built in four model years.
Modern automotive tooling is typically good for roughly 100,000 parts. At that point tooling needs to be refurbished or replaced. In theory that means there should be around 32,000 replacment parts of all kinds, roughly one for every two Thunderbirds, available in dealer inventories or Ford warehouses. Unfortunately, parts production and planning doesn’t always work that way. Carmakers estimate the number of replacement parts of various kinds that may be needed for any production vehicle. The decision of how many parts to produce is based in part on how long certain parts last, and how frequently certain components fail. Items like brake pads and tires require periodic replacement, however, there are many aftermarket providers for such common replacement items.
The real answer may date back to the 2008-2009 financial crisis, which saw automotive giants like GM and Chrysler file for bankruptcy protection and which were ultimately ‘bailed out’ by the federal government. Ford, unlike the others, did not seek bankruptcy protection and refused government aid. While Ford’s action was admired and applauded by many, there were serious financial consequences for Ford’s decision. One of these consequences was the need to cut expenses across the board, and the production of spare parts was one area that was affected. It’s expensive to produce replacement parts and to store them in inventory, so the number of parts for the 2002-2005 Thunderbird were likely reduced from optimal levels.
There were other consequences, however. Ford, like most modern auto manufacturers, relies on a large network of outsource suppliers to manufacture various components for their vehicles. Many of these suppliers are heavily dependent on contracts from large automakers, and the cutbacks that Ford was forced to make caused some suppliers out of business, unable to maintain operations without the large orders from Ford. The company that manufactured the hardtops for the new Thunderbird was one such casualty. Not only was production of hardtops interrupted, but the tooling was tied up in the supplier’s bankruptcy proceedings for years. The hardtop tooling was just recently released and made available to Ford but will likely be scrapped. This is just one example of how supplier problems contributed to parts shortages.
Why is it easier to find replacement parts for a 1957 Thunderbird than for a 2002 Thunderbird?
Another good question … and another puzzling answer. The classic 1955-1957 Thunderbird is one of the most popular collector cars of all time. Though its production numbers were comparable to the 2002-2005 Thunderbird, its soaring value over the years has created huge demand for reproduction parts of all kinds, from mechanical components to trim and accessories. This demand spawned dozens of specialty companies who deal exclusively in parts for vintage Thunderbirds. In fact, it’s possible to build a 1957 T-Bird virtually from the ground up using refurbished, reconditioned and reproduction parts.
Despite a very dedicated following of proud owners, the 2002-2005 Thunderbird is not yet old enough, nor is the demand great enough, to attract the interest of OE aftermarket manufacturers. Producing reproduction parts for any vehicle is a very expensive and time-consuming project. R&D, tooling and manufacturing costs must be amortized over a sufficient number of parts to make the investment financially viable. Sadly, while the need for many parts is great, there’s just not yet enough demand to jusitfy the substantial up-front investment required to make them.
What can I do and how do I find the replacement parts I need?
Here’s the good news. There are already a substantial number of companies who manufacture or recondition OEM quality replacement parts for the new Thunderbird. Components like ECMs (electronic control modules), A/C compressors, and headlights are becoming easier to find. And as demand grows, more and more aftermarket companies will be making replacement parts for the new Thunderbird. Eventually most components for the 2002-2005 Thunderbird should become available through aftermarket companies, but it may take another 10-20 years or longer.
In the meantime there are a number of options. One of the best resources is referals from other Thunderbird owners who have already found a source for the part you may need. Thunderbird owner clubs and online groups are a great source of information about suppliers, manufacturers and specialty companies. Another option is searching the internet. If you have a part number and/or name or ‘call out’ for the part you’re looking for, you can often find it online through Ebay, Amazon or even a Ford dealer. Most Ford dealers can access a nationwide database to search for a particular part, saving you the time and effort of calling multiple dealers. Establishing a relationship with your local Ford dealer’s parts manager can save you time and money, and spare you a lot of frustration. Call around. Some parts managers are more eager to assist than others.
Another possibility is to identify correspondng parts from the Lincoln LS which are compatitble with the ’02-’05 Thunderbird. Both cars were built on the same basic platform and many parts are interchangeable. Be aware, however, that the LS part number will be different from the Thunderbird part number. This is where club members and online forums can be a an invaluable source.
I’ve looked everywhere and the part I need just doesn’t seem to exist … what now?
Some parts just can’t be found. However, the number of those parts is relatively small. Most parts can be tracked down, but it can be a frustrating and time-consuming task. After you’ve checked with your Ford dealer and his parts database, and exhausted your online search for specialty companies and private sellers, you can always turn to salvage yards and auto dismantlers. Parts found through these sources are always used, but may be in excellent condition. They may or may not carry a warranty. Most salvage yards and dismantlers sell ‘as-is, where-is,’ with no guarantee. Also, unless you visit the salvage yard in person, it may be difficult to be certain that a part a dismantler has is the one you need. Salvage yards don’t usually catalog parts using factory part numbers. You may have to rely on general descriptions and/or photos to make sure you’re getting the correct part.
If all else fails … call us!
We specialize in locating and sourcing hard-to-find parts for your 2002-2005 Thunderbird! We have access to parts inventories, specialty suppliers and wholesale manufacturers not always available to retail customers, or even Ford dealers themselves. During the 13 years we’ve been in business, we’ve established relationships and discovered sources that most people don’t even know exist. We can’t guarantee we’ll find the part you’re looking for, but if you’ve given up hope or are just tired of searching, give us a try! We may find the part that you thought was unavailable anywhere. And if we can’t find it, you haven’t lost a cent, and you’ll save a lot of time and frustration!
Call 310-589-1000 or visit us online at: www.mytbird.com
We carry many OEM replacement and aftermarket parts as part of our regular product line.
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