cracking noise

[acdii]

I have to believe the reponse depends on the dealership.

 

The ones that are just trying to solve customer issues will have more latitude. The ones that are watching the every penny won't make a move without being reimbursed by corporate. In those cases, acdii is correct and I can see why he says they follow the script. My dealership in NH won't make a move without corporate authorization. They tell me not to even bother with an appointment until they know what the solution is (and invariably how they're getting paid). I'm not passing judgement here; just stating that we might see different responses depending on the dealership.

 

The ability of the technicians is secondary to the business model. They might be awesome but not given authority to solve it on their own.

 

-Harbor

^^that^^

[expresspotato]

So after the CV shaft mine actually got worse. Its much harder and has changed from a cracking sound to one that is a loud thud and can be felt in the accelerator pedal.

[rvlasek]

Still nice and quiet today. Hopefully the noise will not come back in a week. Also got my leather shift knob. Much nicer. "Recall" letter came today for the shift knob . . .

Will be interested once dmt1971 posts concerning if noise has returned after a week or so... my seems to have gotten a little worse, once dealer replaced front passenger side strut and bearing......

[dmt1971]

Still quiet after 4 days.

[sleamiller]

I took mine in to get gear shifter changed and dealer said the grease down the side of car was not from them. They had not added any axle grease or any grease at all. All they did was take off the left front tire. They had another car in the shop with the same problem. I am not sure what they did but it is quieter thank goodness. Now I just wish the voice commands worked.

 

Me-"Dial Bob". Car-"Dialing Matt". Me- "stupid fing car"

[acdii]

 

 

Me-"Dial Bob". Car-"Dialing Matt". Me- "stupid fing car"

Yours does that too?

[rvlasek]

I took mine in to get gear shifter changed and dealer said the grease down the side of car was not from them. They had not added any axle grease or any grease at all. All they did was take off the left front tire. They had another car in the shop with the same problem. I am not sure what they did but it is quieter thank goodness. Now I just wish the voice commands worked.

 

Me-"Dial Bob". Car-"Dialing Matt". Me- "stupid fing car"

Did you have crackling noise as mentioned,

[47Minutes]

Here is the latest on my popping/cracking noise...

 

I've attached my service technician's Hotline Assistance Request. The response from Ford is to use chassis ears on the steering knuckle and drive the vehicle. If the noise is from the steering knuckle, engineering is aware of the concern and is investigating to determine and repair the root cause. They suspect it is caused by a halfshaft spline to wheel bearing hub spline interference concern.

 

I'll likely get my car back tomorrow or in a couple days depending on the body shop schedule for repair of a paint defect to my rear bumper.

 

Fun Times!

 

FORD HOTLINE.pdf

[GrySql]

They suspect it is caused by a halfshaft spline to wheel bearing hub spline interference concern.

Well, that's new information.

Thanks for letting us know.

Edited April 22, 2013 by GrySql

[rvlasek]

Here is the latest on my popping/cracking noise...

 

I've attached my service technician's Hotline Assistance Request. The response from Ford is to use chassis ears on the steering knuckle and drive the vehicle. If the noise is from the steering knuckle, engineering is aware of the concern and is investigating to determine and repair the root cause. They suspect it is caused by a halfshaft spline to wheel bearing hub spline interference concern.

 

I'll likely get my car back tomorrow or in a couple days depending on the body shop schedule for repair of a paint defect to my rear bumper.

 

Fun Times!

 

Appreciate update, my dealer tech used chassis ears and traced to right front strut and bearing which they changed but did not cure noise, dont' know if they used ears on steering knuckle as your tech mentioned, I take they are not sure, think its a waiting game till they trace it down and maybe used the data from the various failed fixes to find the right one...thanks....

[gkinla]

Short story on cracking noise.

 

Started hearing/noticing cracking noise around 1000 miles.

 

Brought to dealer, inspected wheels and spindles. Re-torqued front axle spindles noise didn't go away. Packed spindles with heavy grease, noise did go away for one week.

 

Noise returned, I just drove the car with the cracking noise for several thousand miles hoping there would be witness marks that the tech would be able to see when inspected.

 

Returned car, re-inspected axles, no witness marks, the dealer ordered new spindles, two weeks later the dealer called that the parts were in.

 

Replace the spindles at approx. 3000 miles, now at 4100 miles the noise is returning.

 

I was at the dealer today, I think Ford has stopped throwing parts at the problem hoping something sticks, I don't think the problem noise is dangerous so I'll keep driving, checking this forum and keep in touch with my dealer. I still like the FFH and will continue to enjoy driving it, hopefully something will happen soon.

[rvlasek]

Short story on cracking noise.

 

Started hearing/noticing cracking noise around 1000 miles.

 

Brought to dealer, inspected wheels and spindles. Re-torqued front axle spindles noise didn't go away. Packed spindles with heavy grease, noise did go away for one week.

 

Noise returned, I just drove the car with the cracking noise for several thousand miles hoping there would be witness marks that the tech would be able to see when inspected.

 

Returned car, re-inspected axles, no witness marks, the dealer ordered new spindles, two weeks later the dealer called that the parts were in.

 

Replace the spindles at approx. 3000 miles, now at 4100 miles the noise is returning.

 

I was at the dealer today, I think Ford has stopped throwing parts at the problem hoping something sticks, I don't think the problem noise is dangerous so I'll keep driving, checking this forum and keep in touch with my dealer. I still like the FFH and will continue to enjoy driving it, hopefully something will happen soon.

Good Info, thanks,,, A Forum POLL need to started to detail, owners with this noise issue, what fixes have been tried, successful or not , so that hopefully someone at FORD to run down the problem quicker.....................

[acdii]

So they now think its the spindle splines making the noise? At the hub? Usually these are fairly tight, and need to be removed with an air hammer, or smacked out with a BFH. It they have enough slop to make noise, even when torqued, then there should be wear marks on the spindles. Going to follow this one closely.

[GrySql]

Good Info, thanks,,, A Forum POLL need to started to detail, owners with this noise issue, what fixes have been tried, successful or not , so that hopefully someone at FORD to run down the problem quicker.....................

Brake pads, rotors, hubs and spindles, CV assemblies, struts and bushings, steering knuckle with hub and spline noise, re-surface rotors, torque all CV nut/suspension bolts, re-pack CV's.....

What else...?

No mention of transmission or motor mounts.

What else is left up front that moves, or torques when the car accelerates or stops?

Only Ford Engineering knows.

 

Ford has to move on this, they are getting farther behind every day and without an aggressive campaign to fix this the whole issue will get out of hand.

Edited April 23, 2013 by GrySql

[hybridbear]

So after the CV shaft mine actually got worse. Its much harder and has changed from a cracking sound to one that is a loud thud and can be felt in the accelerator pedal.

Sounds like what we've been experiencing all along.

 

Here is the latest on my popping/cracking noise...

 

I've attached my service technician's Hotline Assistance Request. The response from Ford is to use chassis ears on the steering knuckle and drive the vehicle. If the noise is from the steering knuckle, engineering is aware of the concern and is investigating to determine and repair the root cause. They suspect it is caused by a half shaft spline to wheel bearing hub spline interference concern.

 

I'll likely get my car back tomorrow or in a couple days depending on the body shop schedule for repair of a paint defect to my rear bumper.

 

Fun Times!

 

So they now think its the spindle splines making the noise? At the hub? Usually these are fairly tight, and need to be removed with an air hammer, or smacked out with a BFH. It they have enough slop to make noise, even when torqued, then there should be wear marks on the spindles. Going to follow this one closely.

Can someone explain what this means? What is the steering knuckle? Where are these splines? I'm not familiar with these parts and a Google search hasn't provided me with a good explanation.

 

Thanks!

[acdii]

Sounds like what we've been experiencing all along.

 

Can someone explain what this means? What is the steering knuckle? Where are these splines? I'm not familiar with these parts and a Google search hasn't provided me with a good explanation.

 

Thanks!

 

Steering knuckle holds the hub, spindle, brake rotor, wheel. Its the piece that is attached to the lower ball joint and strut.

 

 

Splines are the grooves on the axle shaft that mesh with splines on the inside of the hub, which also contains the wheel bearings. In 95% of all FWD cars this is a one piece unit and press fit into the steering knuckle. There is a large nut that is screwed onto the axle shaft where it passes through the hub, and is torqued tight to prevent any slop. If there is any play in the grooves between the axle and hub, no matter how tight you torque that nut, there will still be movement, and this will create a noise like we all are hearing.

 

Not saying this IS the noise we are hearing, just that it does make this kind of noise. Packing it with grease will quiet it down, until the grease gets squished out.

[JSKershaw]

Perhaps it has something to do with the Electric motor. It seems to happen when switching from regen to accel mode. I have the same sound, but always attributed it with the mode of the electric motor changing. Perhaps it a relay?

[GrySql]

Perhaps it has something to do with the Electric motor. It seems to happen when switching from regen to accel mode. I have the same sound, but always attributed it with the mode of the electric motor changing. Perhaps it a relay?

That would be interesting if it was, because Ford Engineering (and the Dealers) are totally concentrating on the suspension, never a comment on any Hotline about the eCVT, Traction motor or other hybrid components, electrical or otherwise.

[lmp180psu]

The noise happens on mine only when accelerating or decelerating in EV mode, not during the transition to/from EV to ICE. It may happen when on ICE only occassionally but if it does it is rare. I can hear it over the stereo many times when the windows are down too. Not a quality sound to hear for sure.

Edited April 23, 2013 by lmp180psu

[JSKershaw]

That would be interesting if it was, because Ford Engineering (and the Dealers) are totally concentrating on the suspension, never a comment on any Hotline about the eCVT, Traction motor or other hybrid components, electrical or otherwise.

This could be because the cost to repair or replace electrical components would be higher than replacing suspension parts. Obviously replacing suspension parts aren't fixing the issues (obviously dealerships are using process of elimination, start with the cheaper parts and move toward more costly parts). Perhaps they need to look deeper into the eCVT and electric motor. The sound on mine does seem to come from the left front (driver side). Isn't that where the electric motor is located under the hood? Hopefully Ford figures this out before it becomes a major problem with breakdowns etc.

Edited April 23, 2013 by JSKershaw

[neod192]

I don't hear this on my car yet (only 500 miles), but if it starts happening and they can't fix it after 4 attempts the Michigan lemon law kicks in:

 

"A defective vehicle is one in which the same problem has not been repaired after four attempts, or a vehicle that is out of service 30 days or more for repairs. The first report of the defect must be made within one year from the date of delivery to the original purchaser or lessee or during the term of the manufacturer's warranty, whichever period is shorter."

[47Minutes]

I don't hear this on my car yet (only 500 miles), but if it starts happening and they can't fix it after 4 attempts the Michigan lemon law kicks in:

 

"A defective vehicle is one in which the same problem has not been repaired after four attempts, or a vehicle that is out of service 30 days or more for repairs. The first report of the defect must be made within one year from the date of delivery to the original purchaser or lessee or during the term of the manufacturer's warranty, whichever period is shorter."

 

And this is probably contributing to Ford's current mandate for dealerships to stop throwing parts at the issue until they officially weigh in on the solution.

[gkinla]

The noise I heard came from the front right and left equally. The tech that drove with me heard this also.

The noise was three distinct clicks on acceleration then three clicks on deceleration using brakes, from both sides. This was not hard acceleration or deceleration. I didn't make any difference if

it was just the traction motor or the ICE was running. Some cold mornings the ICE was on due to cabin heat needed, then later in the day after things warmed up it would make the

same noise just using the traction motor. This makes me think it's clearances being taken up on acceleration and released on deceleration. Just my observation and thoughts.

Edited April 23, 2013 by gkinla

[acdii]

Its torque that is making the noise. So it will happen whether its on ICE or not, you just don't hear it as much if the ICE is on. I would not be too concerned on this yet as Ford will eventually determine the fix for it and replace whatever is causing it. Its more of an annoyance than anything, that's why I never bothered taking it in for that noise.

 

There is play somewhere in the driveline, maybe a bushing in the differential is needed, a tolerance in the hub to shaft area is off, or something else internally is causing it. When Ford figures it out, which they should considering how many cars so far are having this, they will most likely issue another letter to owners to bring it in and have the service done.

[GrySql]

I received an Email from Ford's Quick Touch Survey wanting me to rate my Dealer. I have a great Dealer, now.

I rated my Dealer as good as they can be, considering the Ford Hotline's reluctance (or inability) to provide a fix for many problems.

In a 'Your Comment's' section I included this Forum Topic thread URL for them to read, and asked them to get off the mark and deal with this front end suspension issue that is so widespread.

 

Probably means nothing but I was happy to give my opinion when so many of us love these cars and they can't seem to get it right and fix them without a 'crisis' meeting in a boardroom somewhere.

The simple common sense doctrine of 'fix them and they will like us even more' thinking seems lacking, or underfunded.

I clicked the box for them to contact me if they choose, I'd like to talk to them. I'll hold my breath. ;)