A Pillar - Creaking Noise
Article No.96-25-15
12/02/96
NOISE - "CREAKING" IN A-PILLAR WHEN GOING OVER BUMPS AND/OR TURNING - VEHICLES BUILT THROUGH 12/31/96
FORD:
1996-97 TAURUS SHO, TAURUS
LINCOLN-MERCURY:
1996-97 SABLE
ISSUE:
A "creaking" noise may be heard from the A-pillar area primarily when going over bumps and/or out of driveways. This may be caused by metal contact in areas between the front apron and body side panel.
ACTION:
Weld metal in the contact area to reduce the possibility of noise. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Figures 1, 2 and 3.
1. Remove the leaf (cowl vent) screens from the vehicle. Refer to the 1996 or 1997 Taurus/Sable Service Manual, Page 01-02-16 (1996) or 01-02-14 (1997), for details.
2. Lift edge of windshield "rehau" moulding at bottom and inspect the area identified in Figures 1 and 2 for any contact between the front apron and the body side panel. In some cases, the assembly plants have welded this area for containment. Be sure not to mistake a puddle weld for metal contact.
3. If contact exists, remove the hood and hood hinges. Refer to the 1996 Taurus/Sable Service Manual, Page 01-02-04 for details.
4. Raise the vehicle and remove the wheel.
5. Remove the front fender rear splash shield. Refer to the 1996 or 1997 Taurus/Sable Service Manual, Page 01-02-13 (1996) or 01-02-10 (1997) for details.
6. Remove seven (7) bolts attaching the fender to the body (three attaching the fender to the upper radiator support, two attaching to the body side brackets and two attaching to the front fender apron).
NOTE:
IT IS NOT NECESSARY TO REMOVE THE TWO (2) BOLTS AT THE BOTTOM, REAR OF THE FENDER AT THE SILL MOULDING OR THE ONE (1) BOLT BEHIND THE HEADLAMP.
7. Remove one (1) screw attaching the cowl top extension to the front fender apron.
8. Move the top rear corner of the fender approximately 51-76 mm (2-3") away from the A-pillar to gain access to the area to be worked.
CAUTION:
PRIOR TO WORKING IN THIS AREA, IT IS RECOMMENDED THAT THE ENGINE COMPARTMENT, WINDSHIELD AND "REHAU" MOULDING, OUTSIDE MIRROR, A-PILLAR AND FENDER BE COVERED WITH A WELD BLANKET OR EQUIVALENT TO PREVENT DAMAGE DURING WELDING. IT MAY BE NECESSARY TO TAPE THE WELD BLANKET DOWN AROUND THE AREA TO BE WORKED IN ORDER TO PROPERLY PROTECT THIS AREA.
9. Insert a 51-76 mm (2-3") square wood block or equivalent spacer between the fender and the A-pillar to keep the fender away from the body while working.
10. Remove the paint and E-coat on both the front apron and body side panels in the area of contact.
11. Puddle/Tack weld between the front apron and body side panel.
CAUTION:
BE SURE TO DISCONNECT THE NEGATIVE BATTERY CABLE BEFORE WELDING.
12. Re-evaluate the vehicle to verify the "creak" has been eliminated.
13. Cover the repaired area with primer and touch-up paint.
14. Reinstall the fender, splash shield, wheel, battery, cowl extension and leaf screen (cowl vent) by following the procedures outlined in the 1996 or 1997 Taurus/Sable Service Manual.
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
962515A Repair As Outlined - Both 1.8 Hrs.
Sides
962515B Repair As Outlined - One 1.3 Hrs.
Side
DEALER CODING
CONDITION
BASIC PART NO. CODE
3802010 61
OASIS CODES: 111000, 702000, 702100, 702300