Cracking noise FIX

[elle]

Starting a new thread so that this information does not get buried in the old ones:

 

 

With a little creative Googling, I discovered the existence of FordServiceContent.com ... and with some URL parameter adjustments, I was able to pull up the relevant TSB, TSB 13-5-24:

http://www.fordservi...tsb13-05-24.htm

 

 

 

This was posted by someone else in the cracking noise thread.

[Jaw-Knee]

Anybody have it done yet? Want to know if it actually works!

[jeff_h]

And I was wondering if there were ramifications to NOT getting the TSB done, in other words does the click/pop mean that some component is wearing and needs that part to mitigate it, or is the only drawback that you hear a click/pop now and then but otherwise it does no harm to leave it alone? The details in the TSB don't go any deeper than just making the fix.

[GrySql]

And I was wondering if there were ramifications to NOT getting the TSB done, in other words does the click/pop mean that some component is wearing and needs that part to mitigate it, or is the only drawback that you hear a click/pop now and then but otherwise it does no harm to leave it alone? The details in the TSB don't go any deeper than just making the fix.

Yes, what else could it be than a 'wearing' sound?

Looking at the TSB pictures makes it clear there is an space created between the hub and the half-shaft's wheel bearing mating surface where none should exist.

What part was engineered or manufactured incorrectly so that the clearance or tolerance needs to be adjusted with a 'shim' to prevent the audible shifting/wear noise in the assembly.

Why is there a cutoff date to the 'fix' when we have cars made after that date with the same noise?

 

On the other hand, maybe it was like the missing 505 Pkg leather shifter knob and the Hermosillo Plant just didn't put the thrust washer on the half-shaft during assembly.

Maybe they were out of stock that day.

Makes one wonder what the QA folks are doing on the assembly line.

 

If your car is NOT making the offending noise, it would be interesting to see if it has a thrust washer where the TSB says one should be.

 

Well, it could be worse - I'm glad my emergency brake is working correctly (knock on wood).

[acdii]

Doesn't really add up, but then again not seeing the entire assembly I cant say anything more. It is exactly what I thought it might be, but why would you need a shim there? That would mean there is something preventing the axle from fully seating against the hub. I can understand if the flare at the base of the shaft is larger then the cone in the hub, so torquing it to specs wont draw it in, so maybe that is the problem. The thrust washer(shim) takes up that gap then locking the axle to the hub. I would have to see the back of the hub and the shaft on know for sure if thats the case.

[acdii]

I took a closer look at the pics and now know why it makes the clicking sound. The mating face on the shaft it flat, and the mating surface on the bearing must have a slight taper, so torquing to specs would not fully seat the shaft to the hub, and over tightening the shaft nut would distort the bearing, so you could never fully resolve it without the washer. It has a taper to it to make up the difference.

 

For those who have had service done already where they tightened everything, and "fixed" the Click, you might want to take it back since they may have distorted the wheel bearings in doing so.

[jeff_h]

I took a closer look at the pics and now know why it makes the clicking sound. The mating face on the shaft it flat, and the mating surface on the bearing must have a slight taper, so torquing to specs would not fully seat the shaft to the hub, and over tightening the shaft nut would distort the bearing, so you could never fully resolve it without the washer. It has a taper to it to make up the difference.

 

So with the above in mind, if it is left alone will there be undue wear over time and lead to problems, or just that sound that is harmless?

[GrySql]

 

So with the above in mind, if it is left alone will there be undue wear over time and lead to problems, or just that sound that is harmless?

I'd take my car in and have it checked, I doubt the sound is harmless over time.

That assembly should be silent and just because your particular car does not make the noise loud enough to be noticeable now it may start at a later date.

You have a build date car that is included in the TSB, that is enough for me.

[kuzzi]

This was posted 8 days before our vehicles.

 

http://www.fordservicecontent.com/Ford_Content/pubs/content/~WT/~MUS~LEN/3588/tsb13-05-14.htm

 

For various other vehicles experiencing the same issue.

 

Edit: Fixed my maths - 8 days

Edited May 23, 2013 by kuzzi

[acdii]

 

So with the above in mind, if it is left alone will there be undue wear over time and lead to problems, or just that sound that is harmless?

Yes. Whenever a part moves against another part there will be wear. The noise is the spindle moving into the hub on acceleration, and away from the hub on braking. The more movement, the louder it gets. What will get worn will be the splines inside the hub and the shaft. This is why when it was greased up the noise went away, since the grease cushioned the parts.

[jeff_h]

You have a build date car that is included in the TSB, that is enough for me.

 

OK, to put it a different way, if it was important enough that wear would occur and cause bigger issues on down the road, wouldn't a recall be issued instead of just a TSB? Admittedly I don't know what the criteria are for either, whether it's severity or agency involved or whatever...

 

I'll get it done as now I've now heard a couple ping pong drops from the left side, but wondering why a recall wasn't issued if it was urgent?

[GrySql]

A Recall is the worst PR nightmare for a car company.

So far this is a nuisance and a TSB is a far better way for Ford to deal with it.

[acdii]

They most likely will start another letter campaign like they did for the shifter and headliner.

[hybridbear]

 

OK, to put it a different way, if it was important enough that wear would occur and cause bigger issues on down the road, wouldn't a recall be issued instead of just a TSB? Admittedly I don't know what the criteria are for either, whether it's severity or agency involved or whatever...

 

I'll get it done as now I've now heard a couple ping pong drops from the left side, but wondering why a recall wasn't issued if it was urgent?

I believe that recalls are only for safety issues. If this has not been found to be a safety issue then there won't be a recall. At least that's my understanding of recalls vs TSBs

[47Minutes]

The below quote from my service advisor has me concerned about my Fusion Energi with a build date not included in the TSB...

 

"The tech is already aware of that tsb. Your vehicle is already equipped with those plates on the shaft. Ford is still in the process of finding out why they still make that noise"

[acdii]

Man, if thats doesnt deserve a facepalm, I dont know what does!

[elle]

Huh? I'm so confused. Is this, or is this not, a fix for the clicking problem? I sent this to my dealer and have not yet heard anything back. Will follow up in a day or two.

[gkinla]

I was at my dealer today for an oil change. I downloaded the TSB 13-5-24 to my iPad and showed it to my Service Advisor. He looked it up and ordered parts for the "FIX". Said the parts were on back order, delivery date,?. Soon I hope.

[GrySql]

Huh? I'm so confused. Is this, or is this not, a fix for the clicking problem? I sent this to my dealer and have not yet heard anything back. Will follow up in a day or two.

Elle, this 'Fix' thread to end all the confusion is getting confusing!

Ford says that our FFH's need a 'Thrust Washer' for the Fix, we now find out the Dealers cannot even obtain them, then if installed they may not solve the problem.

 

Looks like you're going to have to start a 'Fixed the Fix' Topic when Ford, once again, finds the Final Fix.

That's a lot of 'F's.

 

Maybe driving slowly, hybrid style, has more benefits than just good mpg's. The wheels might stay on longer…. :fear:

Edited May 23, 2013 by GrySql

[mokee]

Speaking of wheels staying on (as well as getting 'em off), when service is complete I'd ask them to use a torque wrench (not impact driver) to torque the wheel lugs to spec. Also, In my experience loose wheels made a "popping/clicking" sound.

 

Edit: changed IME to In my experience. Sorry....!

Edited May 24, 2013 by mokee

[jeff_h]

I was at my dealer today for an oil change. I downloaded the TSB 13-5-24 to my iPad and showed it to my Service Advisor. He looked it up and ordered parts for the "FIX". Said the parts were on back order, delivery date,?. Soon I hope.

 

I went to dealer this morning for state inspection on wife's Energi (was bought out of state so needed a VA inspection)... once I got her car checked in, went to parts department and showed them the TSB and asked them to look up the parts listed, he did and did not have any of them in stock - said he could order them but would need to be connected with a work order, I said OK will deal with that in the coming weeks.

[kuzzi]

This was posted 8 days before our vehicles.

 

http://www.fordservicecontent.com/Ford_Content/pubs/content/~WT/~MUS~LEN/3588/tsb13-05-14.htm

 

For various other vehicles experiencing the same issue.

 

Edit: Fixed my maths - 8 days

 

It looks like this part for the Flex and other vehicles uses Nylon or PTFE (for wear?) whereas the Fusion washer is just a metal thrust washer.

Edited May 24, 2013 by kuzzi

[acdii]

Awman, now I am going to be listening to odd sounds from the front of my Flex! Gee thanks a lot for posting that TSB! grrrr

[kuzzi]

If you don't want to wait. I'm going to put the Fuzzi up on the ramps when I get home to see if I have these magical devices installed.

 

http://www.mcmaster.com/#thrust-washers/=mw0ury

[GrySql]

Speaking of wheels staying on (as well as getting 'em off), when service is complete I'd ask them to use a torque wrench (not impact driver) to torque the wheel lugs to spec. Also, IME loose wheels made a "popping/clicking" sound.

What's an IME?