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Ford Falcon. Manual - part 16

100-04-36

Noise, Vibration and Harshness

100-04-36

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A : BRAKE VIBRATION/SHUDDER

Test Step

Result / Action to Take

ROAD TEST THE VEHICLE—LIGHT BRAKING

Check that the wheel and tyres are correct for the vehicle. Inspect the

Yes

tyres for abnormal wear patterns.

Go to A4.

Road test the vehicle. Warm the brakes by slowing the vehicle a few

times from 80–32 km/h (50 to 20 mph) using light braking

Go to A2.

applications. At highway speeds of 89–97 km/h (55-60 mph), apply
the brake using a light pedal force.

Is there a vibration/shudder felt in the steering wheel, seat or
brake pedal?

ROAD TEST THE VEHICLE—MODERATE TO HEAVY

BRAKING

Road test the vehicle. At highway speeds of 89–97 km/h (55-60 mph),

Yes

apply the brake using a moderate to heavy pedal force.

For vehicles with ABS, Go to A3.

For vehicles with standard brakes, Go to A4.

Is there a vibration/shudder?

Vehicle is OK. VERIFY condition with customer.
TEST the vehicle for normal operation.

NORMAL ACTUATION OF THE ABS SYSTEM

DIAGNOSIS

During moderate to heavy braking, noise from the hydraulic control

Yes

unit (HCU) and pulsation in the brake pedal can be observed. Pedal

Go to A5.

pulsation coupled with noise during heavy braking or on loose gravel,

bumps, wet or snowy surfaces is acceptable and indicates correct

The brake system is operating correctly.

functioning of the ABS system. Pedal pulsation or steering wheel
nibble whose frequency is proportioned to the vehicle speed indicates
a concern with a brake or suspension component.

Is the vibration/shudder vehicle speed sensitive?

APPLICATION OF THE PARKING BRAKE

Yes

NOTE:

Begin at the front of the vehicle unless the vibration or shudder

Go to A8.

has been isolated to the rear.

This test is not applicable to vehicles with drum-in-hat type parking

Go to A5.

brakes. For vehicles with drum-in-hat parking brakes, proceed to the
next test. For all other vehicles, apply the parking brake to identify if
the problem is in the front or rear brake. At highway speeds of 89–97
km/h (55-60 mph), lightly apply the parking brake until the vehicle
slows down. Release the parking brake immediately after the test.

Is there a vibration/shudder?

CHECK THE FRONT WHEEL BEARINGS

Check the front wheel bearings. Refer to Wheel Bearing Check in this

Yes

section.

Go to A6.

Are the wheel bearings OK?

INSPECT the wheel bearings. ADJUST or
REPAIR as necessary. TEST the system for
normal operation.

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Noise, Vibration and Harshness

100-04-37

DIAGNOSIS AND TESTING (Continued)

Test Step

Result / Action to Take

CHECK THE FRONT SUSPENSION

Check the front suspension for:

Yes

Go to A7.

broken or loose bolts
damaged springs

REPAIR or INSTALL new components as

worn or damaged lower control arm bushings

necessary. TEST the system for normal

loose or rough front bearings

operation.

uneven tyre wear

Are all the suspension components in satisfactory condition?

RESURFACE THE FRONT BRAKE DISCS

Yes

CAUTION:

Do not use a bench lathe to machine brake discs.

Go to A8.

NOTE:

Follow the manufacturer’s instructions to machine the brake

discs. After machining, make sure the brake disc meets the thickness

Vehicle is OK.

specification.

Refer to Brake Disc Machining in this section. Resurface the front
brake discs. Road test the vehicle.

Is the vibration/shudder present?

CHECK THE REAR SUSPENSION

Check the rear suspension for:

Yes

Go to A9.

broken or loose bolts
damaged or worn springs or spring bushings

REPAIR or INSTALL new components as

worn or damaged upper and lower control arm bushings

necessary. TEST the system for normal

worn or damaged trailing arms

operation.

loose or rough rear bearings

uneven tyre wear

Are all the suspension components in satisfactory condition?

RESURFACE THE REAR BRAKE DISC OR DRUM

Yes

CAUTION:

Do not use a bench lathe to machine brake discs.

CHECK the front suspension for wear or
damage, RESURFACE the front brake discs.

NOTE:

Follow the manufacturers instructions to machine the brake discs. TEST the system for normal operation.

After machining, make sure the brake disc meets the thickness
specification.

Vehicle is OK.

Refer to Brake Disc Machining in this section. Resurface the rear
brake disc or drums. Road test the vehicle.

Is the vibration/shudder present?

PINPOINT TEST B : ENGINE TICKING NOISE

Test Step

Result / Action to Take

CHECK FOR TICKING NOISE AT THE FUEL RAIL

Disconnect the first fuel line clip.

Yes

CHECK for TSB for applicable vehicle. REPAIR

Is the ticking noise gone?

as necessary. TEST the system for normal
operation.

Go to B2.

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100-04-38

Noise, Vibration and Harshness

100-04-38

DIAGNOSIS AND TESTING (Continued)

Test Step

Result / Action to Take

CHECK FOR TICKING NOISE AT THE FUEL INJECTOR

Using an EngineEAR, listen at the fuel injectors by placing a probe on

Yes

each injector. To isolate the faulty injector, disconnect the injector

INSTALL a new fuel injector. REFER to Section

electrical connector and listen for the noise.

303-04a for 2.0L Zetec engine or Section
303-04b for 3.0L (4V) engine. TEST the system

Is the fuel injector the source of the ticking noise?

for normal operation.

Go to B3.

CHECK THE BELT TENSIONER FOR TICKING NOISE

Inspect the front engine accessory drive (FEAD). Check for the belt

Yes

tensioner bottoming at end of travel or not at end of stroke.

INSTALL a new belt tensioner. REFER to
Section 303-05 . TEST the system for normal

Using an EngineEAR, listen at the belt tensioner.

operation.

Is the belt tensioner the source of the noise?

Go to B4.

CHECK THE WATER PUMP FOR TICKING NOISE

Using an EngineEAR, listen at the water pump for ticking noise.

Yes

INSTALL a new water pump. REFER to Section

Is the water pump the source of the noise?

303-03 . TEST the system for normal operation.

Go to B5.

CHECK FOR AN OBSTRUCTION OF THE COOLING FAN

Inspect the cooling fan for obstructions.

Yes

REPAIR or INSTALL a new cooling fan. REFER

Check the cooling fan and shroud for wear or damage.

to Section 303-03 . TEST the system for normal
operation.

Was there an obstruction or does the cooling fan show signs of
damage?

Go to B6.

CHECK THE OIL PUMP FOR TICKING NOISE

Check the oil pump using EngineEARs and probe at the oil filter

Yes

adapter to verify the oil pump as a source.

INSTALL a new oil pump. REFER to Section
303-01a for 2.0L Zetec engine or Section

Is the oil pump the source of the noise?

303-01b for 3.0L (4V) engine. TEST the system
for normal operation.

Go to B7.

CHECK VALVE LIFTERS OR LASH ADJUSTERS FOR

CORRECT OPERATION

Check valve lifter/lash adjuster for correct operation, using

Yes

EngineEARs.

VERIFY customer concern. CONDUCT a
diagnosis of other suspect components.

Are the valve lifters/lash adjusters operating correctly?

INSTALL a new valve lifter/lash adjuster(s).
TEST the system for normal operation.

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100-04-39

Noise, Vibration and Harshness

100-04-39

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST C : FRONT ENGINE ACCESSORY DRIVE BEARING HOOT

Test Step

Result / Action to Take

CHECK THE ACCESSORY DRIVE IDLER AND

TENSIONER PULLEY BEARINGS

Carry out the Vehicle Cold Soak Procedure in this section.

Yes

INSTALL a new pulley/idler. REFER to Section

Key in START position.

303-05 . CARRY OUT the Vehicle Cold Soak
Procedure and TEST the system for normal

Place an EngineEAR probe directly on the pulley center post or bolt to

operation.

verify which bearing is making the noise.

Key in OFF position.

CONDUCT a diagnosis on other suspect

Is either bearing making the noise?

accessory drive components.

PINPOINT TEST D : POWER STEERING MOAN

Test Step

Result / Action to Take

CHECK THE POWER STEERING SYSTEM

Carry out the Vehicle Cold Soak Procedure in this section.

Yes

Go to D2.

Key in START position.

Turn the steering wheel while the noise is occurring and listen for

CONDUCT a diagnosis on other suspect

changes in sound pitch or loudness.

accessory drive components.

Key in OFF position.

Does the sound pitch or loudness change while turning the
steering wheel?

VERIFY THE SOURCE

Key in START position.

Yes

VERIFY that the supply tube to the pump is

Place an EngineEAR probe near the power steering pump/reservoir

unobstructed. CHECK the fluid condition and

while the noise is occurring. While an assistant turns the steering

level. DRAIN the fluid and REFILL. CARRY OUT

wheel, listen for changes in sound pitch or loudness.

the Vehicle Cold Soak Procedure and TEST the
system for normal operation. REFER to Section

Key in OFF position.

211-02 .

Does the sound pitch or loudness change while turning the
steering wheel?

Normal system operation.

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