Body/Frame - Clunk/Pop Noise Heard/Felt While Turning
TSB 10-25-312/23/10
CLUNK/POP NOISE HEARD/FELT UNDER FLOOR
PAN WHILE TURNING - BUILT ON OR BEFORE
11/15/2010
FORD:
2008-2011 F-Super Duty
This article supersedes TSB 10-7-3 to add a production fix date.
ISSUE
Some 2008-2011 F-Super Duty vehicles built on or before 11/15/2010 may exhibit a pop or clunk noise heard/felt under floor pan when turning, and may be more noticeable when cold.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Install Chassis Ear J5P97202 in Rotunda Technician Tool Program or equivalent to the right and left number 1 body support mounts located under the A-pillars.
2. Drive the vehicle using any of the following methods to generate the noise:
a. Approximately 20 MPH (32 Km/h) with aggressive left/right steering inputs.
b. Approximately 10 MPH (16 Km/h) while transitioning from a flat road surface to an inclined surface.
c. Approximately 10 MPH (16 Km/h) drive in a figure eight with steering wheel going lock-to-lock, generally an event that causes some level of frame twist and then returns to normal vehicle attitude.
3. If a noise is heard from either or both of the number 1 body support mounts, proceed to Step 4. If noise is not isolated to either of the number 1 body support mounts, do not continue with this procedure. Use normal diagnostics. Refer to Workshop Manual (WSM), Section 501-00.
NOTE
USE OF AIR TOOLS TO LOOSEN BODY SUPPORT MOUNT BOLTS CAN CAUSE THE CAGE NUTS TO SPIN INSIDE BODY.
4. Use hand tools to loosen the number 1 body support mount bolt(s) from the affected side(s). Use air tools to complete removal of the bolt(s).
5. Use a wire wheel to clean all thread lock material from the threads of the body support mount bolt(s).
6. Apply Motorcraft� Threadlock and Sealer to the threads of the body support mount bolt(s).
7. Reinstall the number 1 body support mount bolt(s) and torque to the high end of specification, 87 lb-ft (118 N.m).
8. Repeat Step 2.
9. If noise is no longer present, remove chassis ear and return vehicle to customer. If noise is still present, loosen all body support mount bolts from the affected side using hand tools except the front end sheet mount (located behind the front bumper). Use air tools to complete removal of the bolts.
10. Use a wire wheel to clean all threadlock material from the threads of the bolts.
11. Raise vehicle cab slightly approximately 1" (25 mm).
12. Install a shim between the floor pan and number 1 upper body support mount that exhibits the noise. (Figure 1)
13. Lower vehicle cab.
14. Apply Motorcraft� Threadlock and Sealer to the threads of all body support mount bolts.
15. Reinstall number 1 body support mount bolt and torque to the high end of secure specification, 87 lb-ft (118 N.m).
16. Reinstall the remaining body support mount bolts and torque to 76 lb-ft (103 N.m).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
102503A 2008-2011 F-Super Duty: 1.1 Hrs.
Remove And Install Body
Mount Bolt, Includes Time
For Road Tests With
Chassis Ear On One (1)
Side (Do Not Use With
Any Other Labor
Operations)
102503B 2008-2011 F-Super Duty: 1.2 Hrs.
Remove And Install Body
Mount Bolts, Includes Time
For Road Tests With
Chassis Ear On Two (2)
Sides (Do Not Use With
Any Other Labor
Operations)
102503C 2008-2011 F-Super Duty: 1.7 Hrs.
Remove And Install Body
Mount Bolt, Noise Still
Present, Install Shim,
Includes Time For Road
Tests With Chassis Ear On
One (1) Side (Do Not Use
With Any Other Labor
Operations)
102503D 2008-2011 F-Super Duty: 2.3 Hrs.
Remove And Install Body
Mount Bolts, Noise Still
Present, Install Shims,
Includes Time For Road
Tests With Chassis Ear On
Two (2) Sides (Do Not
Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
1000155 42
Disclaimer