Frame - Creaking Noise/Cracked
Article No.01-11-9
06/11/01
^ FRAME - CRACKS IN RIGHT REAR # 1
CROSSMEMBER - VEHICLES WITH HIGH
ODOMETER READING OR SEVERE SERVICE -
VEHICLES PRODUCED BEFORE 2/6/2001
^ NOISE - "CREAKING" WHILE TURNING WHEEL OR
DRIVING OVER UNEVEN SURFACES - VEHICLES
WITH HIGH ODOMETER READING OR SEVERE
SERVICE - VEHICLES PRODUCED BEFORE 2/6/2001
FORD:
1997-2001 E SERIES, ECONOLINE
This article is being republished in its entirety to update the model year coverage.
ISSUE
A "creaking" noise may be heard when turning wheel or driving over uneven surfaces on vehicles produced before 2/6/2001. This may be due to a crack on the right rear side of the # 1 crossmember. The crack may start from where the right rear attaching tab for the spring tower is located.
ACTION
Clean and weld the affected area including welding around the right rear attaching tab for the spring tower. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Inspect right rear of the # 1 crossmember (Figure 1 - General Area) for any signs of a crack.
2. If a crack is NOT found, proceed with normal Noise/Vibration/Harshness (NVH) diagnostics. If any crack is found, begin by cleaning the area to be welded completely.
3. Drill holes at the end of the crack to prevent crack expansion.
4. V-grind the crack to ensure proper weld penetration.
5. Use clamps/jacks as necessary to align both sides of the crack.
NOTE
BE SURE THAT TEMPERATURE OF THE METAL DOES NOT EXCEED 760°C (1400°F) DURING WELDING.
6. Weld both sides of the affected areas where possible.
7. Weld around the edge of the right rear attaching tab for the spring tower to the # 1 crossmember of the frame (Figure 1, View A). DO NOT weld the rivet.
8. Clean off weld flash/scale and paint welded sections of the frame.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 99-14-11
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage.
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 305000, 390000, 702000, 702100