Body - Liftgate Rattles on Bumps
TSB 05-23-211/28/05
RATTLE - REAR LIFTGATE OVER BUMPS
FORD:
2006 Explorer
MERCURY:
2006 Mountaineer
ISSUE
Some 2006 Explorer 4drlMountaineer vehicles built prior to 9/16/2005 may exhibit a raffle noise from the right rear liftgate while driving over bumps. This may be due to a poor fit between the body wedge plate assembly (78404C28) and the liftgate side slider (78404C04).
ACTION
If a customer comes in for this condition, verify if the noise is coming from the right liftgate wedge block area. If so, install two (2) pieces of Urethane hard foam from the Rotunda Squeak And Rattle Kit (164-R4900).
SERVICE PROCEDURE
1. Remove the right body side wedge plate assembly (78404C28).
2. Cut two (2) pieces of Urethane hard foam 1/8" x 7/16" x 7/8" (3 mm thick x 12 mm wide x 25 mm long).
3. Stack the two (2) pieces of foam together and install just rearward of the middle support. (Figures 1 and 2)
4. Install the right body side wedge plate assembly. (Figures 3 and 4)
5. Verify repair.
6. If the concern is still present or the vehicle was built on or after 9/16/2005, refer to Workshop Manual, Section 501-03.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
052302A 2006 Explorer, 0.8 Hr.
Mountaineer Built Before
9/16/2005: Install
Urethane, Includes Time
To Road Test Before And
After Repair (Do Not Use
With 40110A)
052302B 2006 Explorer, 1.1 Hrs
Mountaineer Built Before
9/16/2005: Install
Urethane, And Adjust
Liftgate Includes Time To
Road Test Before And
After Repair (Do Not Use
With 40110A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
78404C28 07
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