Steering/Suspension - Single Rear Hub Stud Fracture
TSB 12-2-902/17/12
SINGLE WHEEL STUD FRACTURE ON REAR HUB
FORD:
2006-2011 Fusion
LINCOLN:
2006 Zephyr
2007-2011 MKZ
MERCURY:
2006-2011 Milan
ISSUE
Some 2010 and 2011 Fusion/Milan/MKZ vehicles built between 12/1/2009 and 10/26/2010 may exhibit a single rear wheel stud fracture. A small number of rear brake rotors may have been manufactured with a wheel mounting face that is not flat, potentially resulting in a single wheel stud fracture. Service rear brake rotors are also affected. Service brake rotors that may not be flat on the wheel mounting face were available from December 2009 through approximately January 2011 and could be installed on prior model year(s) (2006-2009) Fusion, Milan and MKZ/Zephyr vehicles.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Remove the wheel and tire assemblies. For additional information, refer to Workshop Manual (WSM), Section 204-04.
2. Clean the wheel mounting surfaces of the rear brake discs with a suitable wire brush.
3. Position a straight edge tool (Central Tools CEN6429 or equivalent) flat against the rear brake disc wheel mounting surface, with the side of the straight edge tool next to or touching the wheel hub. (Figure 1A and B)
4. While holding the straight edge tool flat against the rear brake disc wheel mounting surface, use a feeler gauge to check for flatness. (Figure 1C)
a. If a 0.64 mm (0.025") feeler gauge cannot be inserted between the brake disc wheel mounting surface and the straight edge tool, the rear brake disc is flat and proceed with normal repair.
b. If a 0.64 mm (0.025") feeler gauge can be inserted between the brake disc wheel mounting surface and the straight edge tool, replace the rear brake disc.
5. Remove the rear brake disc, refer to WSM, Section 206-04.
6. Using special tool 204-592 or equivalent remove broken wheel stud from the rear wheel hub.
7. Using two large flat washers and a 12 mm X 1.50 mm nut, install the new stud into the wheel hub. Seat the replaced wheel stud using 54-108 N.m (40-80 lb-ft) of torque on the nut.
8. Remove the nut and flat washers after the new wheel stud is installed.
9. Install a new rear brake disc, refer to WSM, Section 206.04.
10. Reinstall the wheel and torque the lug nuts to 135 N.m (100 lb-ft).
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Warranty/ESP coverage limits/policies/prior approvals are not altered by a TSB. Warranty/ESP coverage limits are determined by the identified causal part and verified using the OASIS part coverage tool.
OPERATION DESCRIPTION TIME
120209A 2006-2011 Fusion, Milan, 0.6 Hr.
2007-2011 MKZ, And 2006
Zephyr: Replace The
Fractured Wheel Stud(s)
And Brake Disc (1) Rear
Wheel
120209B 2006-2011 Fusion, Milan, 0.9 Hr.
2007-2011 MKZ, And 2006
Zephyr: Replace The
Fractured Wheel Stud(s)
And Brake Disc(s) Both (2)
Rear Wheels
DEALER CODING
CONDITION
BASIC PART NO. CODE
2C026 14
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