A/C - Popping From Dash in Defrost Mode
TSB 06-21-1210/30/06
INSTRUMENT PANEL "POP" NOISE IN DEFROSTER MODE
FORD:
2006 Fusion
LINCOLN:
2006 Zephyr
MERCURY:
2006 Milan
ISSUE
Some 2006 Fusion, Milan, and Zephyr vehicles may exhibit an intermittent popping sound coming from the dash area when the climate control system is in the defroster setting. The noise may be heard when the vehicle has soaked in cold or hot temperatures for a period of time and then the climate control is set at opposing temperatures. This will cause a thermal expansion/contraction of the defroster ducts causing the popping noise.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
SOME POPPING SOUNDS FROM THE HEATER A/C DUCTS ARE NORMAL. THIS REPAIR PROCEDURE WILL NOT ELIMINATE ALL POP NOISES BUT WILL SIGNIFICANTLY REDUCE THE FREQUENCY OF THE POPS.
NOTE
FOR FUSION AND MILAN VEHICLES FOLLOW STEPS 1-11. FOR ZEPHYR VEHICLES ONLY FOLLOW STEPS 6-11. ZEPHYR HAS A DIFFERENT DEFROSTER DUCT DESIGN THAT DOES NOT HAVE SNAP TABS AND AS A RESULT IS NOT NECESSARY TO PERFORM THE BONDING PORTION.
1. Remove the passenger side air bag following Workshop Manual (WSM), Section 501-20B.
2. Using a small hand held mirror look at the back side of the duct that can be seen through the passenger side air bag opening. Look for the five (5) snap tabs that are on the back side and make a mark on the front side using a marker so the location is known. (Figure 1)
3. Use Motorcraft Nitrile Technician Gloves and apply Motorcraft Plastic Bonding Adhesive to the back side of each of the snap tabs with the index finger.
NOTE
ROTUNDA PART NUMBER 501-040 APPLICATOR GUN SHOULD BE USED TO DISPENSE THE PLASTIC BONDING ADHESIVE.
4. Apply a bead of plastic bonding adhesive to the edge of the duct opposite to the snap tabs (facing towards the glove box). The intent is to bond the front and rear sections of the defrost duct. (Figure 2) Allow plastic bonding adhesive to cure for 90 minutes before vehicle is returned to the customer.
5. Reinstall air bag following WSM, Section 501-20B.
6. Remove the defroster grille cover following WSM, Section 417-01. Be sure to disconnect the electrical connection to the light sensor (if equipped).
NOTE
IT IS NOT NECESSARY TO REMOVE THE LIGHT SENSOR FROM THE DEFROSTER GRILLE.
7. Use Instrument Panel to Duct Spacer and cut pieces to the following lengths:
a. Vane number 1 = 45/16" (110 mm) in length.
b. Vane number 2 = 2-3/4" (70 mm) in length.
c. Vane number 3 = 2-9/16" (65 mm) in length.
d. Vane number 4 = 2-3/16" (55 mm) in length.
e. Vane number 5 = 2-3/4" (70 mm) in length.
8. Use Figure 3 to match up spacer to correct vane locations.
9. Lubricate each center groove of the five spacers using Motorcraft electrical grease to aid in installation.
10. Using needle nose pliers, slide each spacer in the appropriate vane far enough that the defroster grill can be installed without interference.
NOTE
IF A SPACER WILL NOT GO IN ALL THE WAY, MARK IT WITH A FELT MARKER, REMOVE IT AND CUT SO THAT IT WILL BE SHORT ENOUGH TO CLEAR THE DEFROSTER GRILLE ONCE IT IS REINSTALLED. BE VERY CAREFUL WHEN INSTALLING SPACERS NOT TO DROP THEM IN THE DUCT. IF ONE IS DROPPED INSIDE, THE COMPLETE INSTRUMENT PANEL WILL HAVE TO BE REMOVED TO GET IT OUT.
11. Once all spacers are in place reinstall the defroster grille following WSM, Section 417-01.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
062112A 2006 Fusion/Milan: Inspect, 0.9 Hr.
Perform Service
Procedure, Includes Time
To Remove And Install
Passenger Air Bag (Do
Not Use With 14056D,
14056D5)
062112B 2006 Zephyr: Perform 0.3 Hr.
Service Procedure Steps 6 through 11
DEALER CODING
CONDITION
BASIC PART NO. CODE
18A484 61
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