Exhaust System - Metallic Noise On Cold Start Up
TSB 10-3-503/01/10
2.5L - 10-20 SECOND EXHAUST NOISE AFTER OVER
NIGHT SOAK (EXCLUDES HYBRID)
FORD:
2009 Escape
MERCURY:
2009 Mariner
This article supersedes TSB 09-25-1 to remove the production build date.
ISSUE
Some 2009 Escape and Mariner vehicles equipped with 2.5L engine (excludes Hybrid) may exhibit a metallic exhaust noise during first 10-20 seconds of operation during a cold start (engine off for 2 or more hours). The noise decreases as the exhaust system warms up.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Is exhaust noise only audible during first 10-20 seconds of operation during a cold start (engine off for 2 or more hours)?
a. Yes - Proceed to Step 2.
b. No - Stop as procedure does not apply.
Follow normal Noise, Vibration and Harshness (NVH) diagnostics per Workshop Manual (WSM), Section 100-04.
2. With the vehicle in neutral, position it on a hoist. Refer to WSM, Section 100-02.
NOTE
POSITION HOIST LIFT ARM CLEAR OF EXHAUST HEAT SHIELD.
3. With the exhaust system installed on vehicle, measure 3" (75 mm) from the end of the catalytic converter outlet weld and mark the pipe. Install hose clamps to either side of mark. Using reciprocating saw, cut pipe between the clamps using clamps as a guide. (Figure 1)
4. Remove and discard the muffler portion of the catalytic converter and muffler assembly.
5. De-burr the cut edge of the catalytic converter outlet pipe. Using sandpaper or equivalent, clean the rust from the outside surface of the outlet pipe.
6. Remove and discard the underbody heat shield. If equipped, cut off the body stud for the old heat shield. Replace with new heat shield listed in parts list. Reuse original heat shield fasteners and torque to 3 lb-ft (4 N.m).
7. Loosely install the U-bolt onto the inlet pipe of the new muffler/resonator assembly. Install in vehicle by assembling the resonator inlet pipe over the catalytic converter outlet pipe. Install hangers in rubber insulators.
NOTE
DO NOT TIGHTEN U-BOLT AT THIS TIME.
8. At muffler outlet flange location, install new exhaust fasteners and gasket and tighten per WSM, Section 309-00.
9. With new exhaust installed on vehicle, measure 1" (25 mm) from the end of the catalytic converter outlet weld and mark the pipe. (Figure 2)
10. Slide the muffler assembly forward/rearward so that the edge of the new resonator inlet pipe is aligned with this mark.
11. Locate the U-bolt approximately 25/32" (20 mm) from end of the resonator inlet pipe. Torque the U-bolt to 21 lb-ft (28 N.m), alternating in 5 lb-ft (7 N.m) increments.
CAUTION
OVER TORQUING PAST 21 LB-FT (28 N.m) MAY DISTORT EXHAUST PIPE CREATING EXHAUST LEAK.
12. On 4X4 vehicles, verify the driveshaft safety cable is routed between the heat shield and resonator. (Figure 3)
13. With pliers on the flat metal end of the driveshaft safety cable, bend cable end upward to ensure cable is equal spaced between the new heat shield and resonator. (Figure 4)
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
100305A 2009 Escape, Mariner 0.6 Hr.
2.5L: Replace The Muffler
Assembly Following The
Service Procedure (Do Not
Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
5230 42
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