Suspension/Frame - Rattle/Clunk/Pop/Squeak
Article No.93-22-12
10/27/93
^ FRONT UNDERBODY - "RATTLE", "CLUNK", "POP", "SQUEAK", "CREAK" OR "CRUNCH" NOISE - DIAGNOSTIC PROCEDURE
^ NOISE - "RATTLE", "CLUNK", "POP", "SQUEAK", "CREAK" OR "CRUNCH" FROM FRONT UNDERBODY - DIAGNOSTIC PROCEDURE
LIGHT TRUCK:
1991-93 EXPLORER
1993 RANGER
ISSUE:
A "rattle", "clunk", "pop", "squeak", "creak", or "crunch" noise may be heard from the front underbody. These noises may occur because of worn radius arm bushings, loose front stabilizer bar attaching hardware, loose crossmember to frame attachments, incorrect radius arm bushings or over-tightened radius arm nuts.
ACTION:
Use the following diagnostic procedure along with the list of common sources of noise and recommended repair procedures to determine what the concern is and how to correct it.
DESCRIPTION OF VARIOUS FRONT UNDERBODY NOISES
The following noises may be be heard from the front underbody during normal driving conditions. A brief description of each noise in included to provide consistency during the diagnostic and repair procedures.
^ Rattle - A continuous light metallic noise induced by driving over rough road surfaces (i.e.- tar strips, bumps, patched surfaces). A sound suggesting looseness, such as marbles rolling around in a can.
^ Clunk - A heavy metallic noise heard upon impact of bumps. Typically, a clunk is heard once upon each impact.
^ Pop - It is similar to a clunk, but a lighter sound. It is heard upon impact of rough road surfaces, or during braking. Typically, a pop is heard once upon each impact or brake application.
^ Squeak - A high pitched sound, like rubbing a clean window, heard during suspension movement (jounce or rebound). A suspension squeak may be induced by driving over undulating surfaces, or while jouncing a stationary vehicle.
^ Creak - A creak is similar to a squeak, but usually louder, produced by a metal-to-metal, or rubber to metal, rubbing motion which may occur during suspension movement (jounce or rebound).
COMMON SOURCES OF NOISE AND RECOMMENDED REPAIR PROCEDURES
Various front underbody noises may originate from several different sources. Occasionally, the same type of noise will be produced by different sources. Likewise, a particular cause of noise may produce different noises on different vehicles. The chart identifies several types of noises, potential sources of the noise, and recommended repair procedures.
DIAGNOSTIC PROCEDURE
STEP 1: INTERVIEW THE CUSTOMER
^ Understand the customer's description of the noise.
^ Road test the vehicle with the customer to fully understand where, how and when the noise occurs.
^ Is the noise - speed dependent?, - road surface dependent?, or - temperature/weather dependent?
STEP 2: DUPLICATE THE NOISE CONCERN
^ Is the noise heard while bouncing the bumper of the vehicle?
^ Or, is the noise only heard while driving over rough road surfaces?
^ Or, is the noise only heard while driving while braking?
^ Or, is the noise only heard while turning (while driving, or while parked)?
Typically, front underbody noise is heard while bouncing the bumper of the vehicle. If the noise can not be duplicated during the static bounce, or during low speed turning maneuvers, it most likely is not suspension related.
STEP 3: ISOLATE THE NOISE CONCERN
^ If the noise can be duplicated by pushing up and down on the vehicle while stationary, use a stethoscope or chassis ears to determine the area of the chassis that the noise appears to be coming from.
^ Another method of isolating a noise is to place your hand on the coil spring, radius arm, or stabilizer bar while someone pushes up and down on the vehicle. This will allow you to feel the vibrations. However, this method is sometimes misleading as the vibrations may carry from one suspension component to another.
^ Spray a liberal amount of penetrating oil on the suspension components which appear to be creating the noise. If the noise stops after lubrication, refer to the Recommended Repair Procedures Section above for permanent repair action.
STEP 4: INSPECT THE VEHICLE
Inspect the vehicle in the general area of the source of the noise for the following:
^ Loose fasteners
^ Worn/broken parts
^ Excessive dirt/rust accumulation
STEP 5: SERVICE THE VEHICLE
Service the vehicle in accordance with the 1993 Aerostar, Ranger, Explorer Body/Chassis Service Manual, or the additional repair procedures outlined in this article.
STEP 6: TEST DRIVE THE VEHICLE
Drive the vehicle over the same road surface on which the customer demonstrated the noise to assure the noise was correctly identified and repaired.
STEP 7: FOLLOW-UP WITH THE CUSTOMER
Follow-up with the customer about two weeks after service is performed to assure the noise was correctly identified and repaired.
OTHER APPLICABLE ARTICLES:
92-1-6, 92-14-7, 93-9-14
WARRANTY STATUS:
Eligible Under Bumper To Bumper warranty For 1992/93 Models, Basic Warranty Coverage For 1991 Models
OPERATION DESCRIPTION TIME
932212A Remove, Clean, Lubricate 0.7 Hr.
and Re-install Both Front
Body Mounts
932212B Replace One Spring Tower 0.6 Hr.
Rivet - One Side (Not the
Huck Rivet)
932212C Replace One Spring Tower 1.1 Hrs.
Rivet - Both Sides
(Not the Huck Rivet)
932212D Add for Each Additional 0.3 Hr.
Spring Tower Rivet
Replaced Each Side (Total
Time For Rivet
Replacement Each Side Not
To Exceed 1.2 Hrs.)
DEALER CODING
BASIC PART NO. CONDITION CODE
3B244 30
OASIS CODES:
304000, 390000, 702000, 702100