Ford Falcon. Manual - part 11

100-04-16 

Noise, Vibration and Harshness  

100-04-16

DIAGNOSIS AND TESTING (Continued)

Condition

Source

Action

  Air leak around the liftgate flip window

  PINCH the seal carrier to improve the

Loose fit seal.

perimeter

retention to the seal flange.

Seal misaligned.

  REINSTALL the seal.

Glass misaligned.

  REALIGN the glass.

Seal damaged.

  INSTALL a new seal.

  INSTALL an antenna boot or a spiral

  Wind noise from antenna

Shape of antenna.

antenna.

Air leak around antenna cable access

  INSPECT the antenna access hole

hole.

grommet. REPAIR as necessary.

  Air leak from closed roof opening

Seal installed incorrectly.

  REINSTALL the seal.

panel

Roof opening panel glass/door

  REALIGN the roof opening panel

misaligned.

glass/door.

  INSTALL a new roof opening panel.

Roof opening panel damaged.

REFER to Section 501-17 .

  Buffeting from an open roof opening

  REPAIR or INSTALL a new wind

Wind deflector inoperative/damaged.

deflector as necessary. REFER to

panel

Section 501-17 .

Wind deflector height incorrect.

  ADJUST the wind deflector higher.

  Wind noise created by airflow over or

Fender splash shield misaligned.

  REALIGN the fender splash shield.

behind body panels

Body panel misaligned (exposed

  REALIGN the appropriate body panel.

edge).

  CHECK hood gaps and fit. ADJUST

Hood misaligned (front margin).

the hood as necessary.

  APPLY foam in the hollow areas

Front grille edge noise.

behind the louvers.

  Wind noise created by grille opening

Grille relationship to leading edge on

  ADJUST the grille opening panel

panel

hood.

forward to eliminate wind noise.

Sharp edges due to material

  REMOVE the sharp edges (no

imperfections.

damage to visible surface).

Air extractor housing seated

  Wind noise from air extractor

  REINSTALL the air extractor housing.

incorrectly.

Air extractor housing or flaps

  INSTALL a new air extractor.

damaged.

  Noise from roof rack

Roof rack rails or crossbars loose.

  TIGHTEN the fasteners.

Roof rack fasteners missing.

  INSTALL the approved fasteners.

Roof rack crossbars installed

  REINSTALL the crossbars.

backward.

Roof rack rub strips partially lifting from

  REAPPLY adhesive or fasteners or

roof.

INSTALL new rub strips as necessary.

Roof rack gaskets loose or misaligned.

  REINSTALL the gasket.

  Wind noise from bug shield/exterior

Turbulence created by location and

  REMOVE per customer direction if it is

windshield sun visor

shape.

a dealer installed option.

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100-04-17 

Noise, Vibration and Harshness  

100-04-17

DIAGNOSIS AND TESTING (Continued)

Symptom Chart — Brake Noise/Vibration

Condition

Source

Action

  CHECK the caliper bolts. TIGHTEN to

  Rattling noise

Caliper mounting bolts loose.

specifications. REFER to Section
206-03 .

Damaged or worn caliper pins or

  CHECK the caliper pins and retainers

for lubrication and correct fit.

retainers.

LUBRICATE or INSTALL new
components as necessary.

Missing or damaged anti-rattle clips or

  CHECK the brake pads for missing

clips or broken springs. INSTALL new

springs.

components as necessary. REFER to
Section 206-03 .

  TIGHTEN the brake disc shield bolts to

Loose brake disc shield.

specification. REFER to Section
206-03 .

  Clicking noise—with brakes applied

ABS hydraulic control unit.

  Acceptable condition.

with ABS brakes

  Squealing noise—occurs on first

  Acceptable condition. Caused by

Disc brake pads.

humidity and low disc brake pad

(morning) brake application

temperature.

Disc brake pads worn below minimum

  INSTALL new disc brake pads.

  Squealing noise—a continuous squeal

thickness.

REFER to Section 206-03 .

 Squealing 

noise—an 

intermittent

Disc brake pads.

  Acceptable condition.

squeal brought on by cold, heat, water,
mud or snow

  Groaning noise—occurs at low speeds

Disc brake pads.

  Acceptable condition.

with brake lightly applied (creeping)

Disc brake pads worn below minimum

  INSPECT the brake pads, shoes,

 Grinding 

noise—continuous

brake discs and attaching hardware for

thickness.

damage. REPAIR or INSTALL new
components as necessary. REFER to
Section 206-03 for front disc brakes or
Section 206-02 for rear disks.

Brake linings contaminated with

  INSPECT the brake pads and shoes

 Moaning 

noise

for contamination. REPAIR or

grease or oil.

INSTALL new components as
necessary. REFER to Section 206-03
for front disc brakes or Section 206-04
for rear disks.

  Brake vibration/shudder—occurs when

Uneven disc or drum wear.

Go to PinPoint Test A .

Uneven disc brake pad or lining

brakes are applied

transfer.
Suspension components.

  Brake vibration/shudder—occurs when

  INSPECT the brake pads and shoes

Brake drag.

for premature wear. REPAIR or

the brake pedal is released

INSTALL a new caliper or wheel
cylinder as necessary. REFER to
Section 206-03 for front disc brakes or
Section 206-04 for rear disk brakes.

Symptom Chart—Driveline Noise/Vibration

Condition

Source

Action

  Axle howling or whine—rear axle or

  CHECK the lubricant level. FILL the

Axle lubricant low.

transfer case

axle to specification.

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100-04-18 

Noise, Vibration and Harshness  

100-04-18

DIAGNOSIS AND TESTING (Continued)

Condition

Source

Action

  INSPECT the axle housing for

Axle housing damage.

damage. REPAIR or INSTALL a new
axle as necessary. REFER to Section
205-02 .

Damaged or worn wheel bearings or

  CHECK for abnormal wheel bearing

play or roughness. REFER to Wheel

axle bearings.

Bearing Check in this section.
ADJUST or INSTALL new wheel
bearings as necessary. REFER to
Section 204-01 for front bearings or
Section 204-02 for rear bearings.

Damaged or worn differential ring and

  INSPECT the ring and pinion ring for

abnormal wear patterns or broken

pinion.

teeth. INSTALL a new ring and pinion
as necessary. REFER to Section
205-02 .

Damaged or worn differential side or

  CHECK for abnormal bearing play or

roughness. INSTALL new bearings as

pinion bearings.

necessary. REFER to Section 205-02 .

Damaged or worn differential side

  DISASSEMBLE the differential carrier.

INSPECT the side and pinion gears for

gears and pinion gears.

abnormal wear patterns or broken
teeth. INSTALL new gears as
necessary. REFER to Section 205-02 .

Transfer case housing or internal gear

  INSPECT the transfer case for

damage. CHECK the lubricant level

damage or low lubricant.

and fill transfer case to specification.
REFER to Section 308-07b .

  Driveline clunk—loud clunk when

  CHECK the lubricant level. FILL the

Incorrect axle lubricant level.

shifting from reverse to drive

axle to specification.

Excessive backlash in the axle or

  CARRY OUT a total backlash check.

transmission.

  CHECK for abnormal bearing play or

Damaged or worn pinion bearings.

roughness. INSTALL new bearings as
necessary. REFER to Section 205-02 .

Damaged or worn universal joints

  INSPECT the U-joints for wear or

damage. INSTALL new U-joints as

(U-joints).

necessary. REFER to Section 205-01 .

  INSPECT the suspension for damage

Loose suspension components.

or wear. REPAIR or INSTALL new
components as necessary. REFER to
Section 204-00 .

  INSPECT the powertrain mounts.

Broken powertrain mounts.

INSTALL new mounts as necessary.
REFER to Section 303-01a for 2.0L
Zetec engine or Section 303-01b for
3.0L (4V) engine.

Idle speed too high.

  CHECK for the correct idle speed.

  Driveline clunk—occurs as the vehicle

Worn driveshaft constant velocity (CV)

  INSPECT the CV joint and U-joints for

a worn condition. INSTALL a new

starts to move forward following a stop

joint or U-joints with excessive play.

Driveshaft as necessary. REFER to
Section 205-01 .

  CHECK the axle for loose bolts.

Loose rear axle mount.

TIGHTEN to specification.

  Clicking, popping or grinding—occurs

Inadequate or contaminated lubrication

  CHECK the CV joint boots and joints

for wear or damage. REPAIR or

while vehicle is turning

in the CV joints.

INSTALL new components as
necessary. REFER to Section 205-04 .

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100-04-19 

Noise, Vibration and Harshness  

100-04-19

DIAGNOSIS AND TESTING (Continued)

Condition

Source

Action

Another component contacting the

  CHECK the halfshafts and the area

around the halfshafts. REPAIR as

halfshaft.

necessary.

  INSPECT the front brakes for wear or

Brake components.

damage. REPAIR as necessary.
REFER to Section 206-03 .

  INSPECT the drag link, inner and

Steering components.

outer tie-rods or idler arm for wear or
damage. REPAIR as necessary.
REFER to Section 211-00 .

  INSPECT the upper and lower ball

Suspension components.

joints for wear or damage. REPAIR as
necessary. REFER to Section 204-01
for front ball joints or Section 204-02
for rear ball joints.

  CHECK for abnormal wheel bearing

Damaged or worn wheel bearings.

play or roughness. REFER to Wheel
Bearing Check in this section.
ADJUST or INSTALL new wheel
bearings as necessary. REFER to
Section 204-01 for front wheel
bearings or Section 204-02 for rear
wheel bearings.

  High pitched chattering—noise from

  CHECK the vehicle by driving in tight

Incorrect or contaminated lubricant.

the rear axle when the vehicle is

circles (5 clockwise, 5
counterclockwise). FLUSH and

turning

REFILL with the specified rear axle
lubricant and friction modifier as
necessary.

Damaged or worn differential

  DISASSEMBLE the differential

(differential side gears and pinion

assembly. INSPECT the differential
case, pin and gears for wear or

gears).

damage. REPAIR or INSTALL a new
differential as necessary. REFER to
Section 205-02 .

  Buzz—buzzing noise is the same at

  CHECK for abnormal tyre wear or

Damaged or worn tyres.

damage. INSTALL a new tyre as

cruise or coast/deceleration

necessary. REFER to Section 204-04 .

  CHECK for correct driveline angles.

Incorrect driveline angles.

REPAIR as necessary. REFER to
Section 205-00 .

  Rumble or boom—noise occurs at

  CHECK the driveshaft for damage,

Driveshaft is out-of-balance.

coast/deceleration, usually driveshaft

missing balance weights or

speed related and noticeable over a

undercoating. Using the Driveline
balancer, CHECK the driveshaft

wide range of speeds

balance. CARRY OUT a driveline
vibration test. REFER to Section
205-00 . REPAIR as necessary.

  ROTATE the driveshaft and CHECK

U-joints binding or seized.

for rough operation or seized U-joints.
INSTALL new U-joints as necessary.
REFER to Section 205-01 .

  CARRY OUT a runout check. REPAIR

Excessive pinion flange runout.

as necessary.

  Grunting—normally associated with a

  CLEAN the CV joint and INSTALL a

Driveshaft CV joint binding.

shudder experienced during

new driveshaft as necessary. REFER

acceleration from a dead stop

to Section 205-01 .

Loose rear axle mount bolts or

  INSPECT the rear suspension and

axle. TIGHTEN the fasteners to

suspension fasteners

specification.

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