Exhaust System - Moan and/or Vibration

Article No.
95-3-8

02/13/95

^ EXHAUST - MOAN/VIBRATION - 3.8L NON-SC

^ MOAN - VIBRATION - EXHAUST - 3.8L NON-SC

FORD:
1992-95 THUNDERBIRD

LINCOLN-MERCURY:
1992-95 COUGAR

ISSUE:
A moan and/or vibration may occur from the exhaust at about 2800 to 3000 RPM when under moderate acceleration.

ACTION:
If this condition occurs install exhaust system damper and rear frame support damper. Use the following procedures.

NOTE:
THIS TSB APPLIES TO 3.8L NON-SC ENGINES ONLY.

EXHAUST SYSTEM DAMPER PROCEDURE

1. If exhaust system is suspect to the noise condition, use the diagnosis and testing procedures for exhaust system per the appropriate Thunderbird/Cougar Service Manual, Group 09, Section 00.

2. If moan/vibration has been isolated as being in the exhaust system, inspect complete exhaust system and remove any weights or dampers that may have been previously installed.





3. Install exhaust damper (F4SZ-5F240-A) on left hand (driver side) pipe between converter housing and bend in front of resonator (muffler). Refer to Figure 1 for location.

4. When properly installed, the exhaust damper U-bolts will be positioned to the rear of the vehicle and the damper body toward the front. The rear U-bolt will be located in front of the exhaust pipe bend before the pipe diameter change. The damper body should be located horizontal to the converter pipe.

NOTE:
DAMPER MUST NOT HANG BELOW EXHAUST CONVERTER PIPE.

5. Ensure a minimum of 0.75" (19 mm) exists between the damper body and the floor pan to avoid rattles.

6. Ensure front U-bolt does not interfere with the transmission shift linkage.

7. Torque U-bolt clamps to 25-35 lb.ft. (34-47 N-m).

FRAME SUPPORT DAMPER PROCEDURE

1. Remove # 3 crossmember insulator support nut (N803742-S36). Refer to Figure 1.

2. Position frame support damper assembly (F3LY-5D008-A) on center of support using the index tabs to correctly position the damper on the support.

3. Reinstall insulator support nut.

4. Torque insulator nut to 75 lb.ft. (102 N-m).

IMPORTANT:
This TSB requires both dampers to be installed. Installation of only one (1) damper will be ineffective.

PART NUMBER PART NAME

F4SZ-5F240-A Exhaust System Damper
F3LY-5DOO8-A Rear Frame Support Damper Assembly

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

OPERATION DESCRIPTION TIME
950308A Align Exhaust System And 0.7 Hr.
Install Dampers

DEALER CODING
BASIC PART NO. CONDITION CODE
5DO08 OR
5F240 56

OASIS CODES:
403000, 497000, 702000, 702300, 703000,703200