Subframe - Clunk When Accelerating/Decelerating

Article No.
95-24-5

12/04/95

^ FRAME - SUBFRAME INSULATORS - "CLUNK" ON HEAVY ACCELERATION AND/OR DECELERATION HEARD OR FELT IN FLOOR PAN AREA - VEHICLES BUILT THROUGH 1/1/96

^ NOISE - "CLUNK" - ON HEAVY ACCELERATION AND/OR DECELERATION - MAY BE HEARD AND/OR FELT IN FLOOR PAN AREA - VEHICLES BUILT THROUGH 1/1/96

LIGHT TRUCK:
1995-96 WINDSTAR

ISSUE:
A "clunk" noise on heavy acceleration and/or deceleration or on turns may be heard and/or felt in the floor pan area. This may be caused by the upper subframe insulators allowing movement between the body and the subframe.

ACTION:
Replace the upper subframe insulators. The new insulators (F68Z-5C148-AA) are designed with case hardened nibs on the upper surface to reduce the possibility of movement and noise. Refer to the following Service Procedure for details.

SERVICE PROCEDURE

1. Support the rear subframe. Loosen the left rear subframe bolt and then the right rear subframe bolt. Lower the rear subframe while still supported.

2. Remove the existing left upper subframe insulator and replace it with an updated subframe insulator. Remove the existing right upper subframe insulator and replace it with an updated subframe insulator.

3. Raise the subframe and maintain rear subframe support during the torquing of the subframe-to-body bolts to 80 + 12 N.m (59 + 9 lb-ft).

CAUTION:
DO NOT TORQUE THE SUBFRAME BOLTS WITHOUT SUPPORTING THE REAR SUBFRAME. BE SURE TO USE THREAD LOCK ADHESIVE (EOAZ-19554-AA OR EQUIVALENT) ON ALL REAR SUBFRAME BOLTS BEFORE REINSTALLING AND TORQUING. THE SUBFRAME MUST BE SUPPORTED DURING SERVICE USING ROTUNDA HI-LIFT JACK (014-00210) AND ROTUNDA SUBFRAME REMOVAL KIT (014-00751).

4. With the rear subframe bolts torqued to specification, move the support jack forward and position it so that it now supports the front subframe. Loosen the left front subframe bolt and then the right front subframe bolt. Lower the subframe while maintaining support.

5. Remove the existing left upper subframe insulator and replace it with an updated subframe insulator. Remove the existing right upper subframe insulator and replace it with an updated subframe insulator.

6. Raise the subframe and maintain front subframe support during the torquing of the subframe-to-body bolts to 80 + 12 N.m (59 +/- 9 lb-ft).

CAUTION:
DO NOT TORQUE THE SUBFRAME BOLTS WITHOUT SUPPORTING THE REAR SUBFRAME. BE SURE TO USE THREAD LOCK ADHESIVE (EOAZ-19554-AA OR EQUIVALENT) ON ALL REAR SUBFRAME BOLTS BEFORE REINSTALLING AND TORQUING. THE SUBFRAME MUST BE SUPPORTED DURING SERVICE USING ROTUNDA HI-LIFT JACK (014-00210) AND ROTUNDA SUB FRAME REMOVAL KIT (014-00751).

PART NUMBER PART NAME
F68Z-5C148-AA Subframe Insulator
EOAZ-19554-AA Thread Lock Adhesive

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage

OPERATION DESCRIPTION TIME
952405A Replace Subframe Insulators 0.6 Hr.

DEALER CODING
CONDITION
BASIC PART NO. CODE
5C148 56

OASIS CODES: 111000, 304500, 304597, 305000, 702000, 702100, 702300