I have a 2012 Ford Supercrew, 6.5 FT bed, Ecoboost that I got in April. About two weeks after I got it, someone ran a two way stop right out in front of me and I hit them on my drivers side front. Damage pretty minimal considering their car was totaled. I had my truck back from the body shop about two weeks later. Everything was great.

About 3 weeks after I had gotten my truck back, I began to notice a strange noise that sounded almost like someone was opening a door really slow. (more of a rapid popping sound than a high pitched squeak) It only happened on acceleration and the sound was coming from the passenger side right up next to the firewall. I figured it was something that wasnt tightened correctly from the body work. I took it to Ford for warranty work and told them this story...they werent concerned about the wreck. They suspected suspension...I agreed this was probable.

They checked and tore down the whole front suspension on the passenger side. They ended up replacing that whole side with brand new parts, new shock, upper lower control arms, new coil, gaskets, etc. Problem was still not fixed.

I took it back to the body shop where it was worked on and had the foreman ride with me so he could listen to noise. He said that he believed it was the suspension as well. He said that most of the bushings that sit on top of the coil come from the factory sort of dry...he suggested breaking it down and putting teflon grease between the bushing and the top of the coil tower that mounts to the frame. He said he has had luck with that.

Long story short, the driver side began doing the same thing. I took it back to Ford and they agreed to try what the body shop foreman had told me. Still no luck!

My front suspension has been replaced and broken completely down three times, tightened back up to factory specs, and re-aligned...and still no fix!

It sounds like a truck with 250,000 miles when I first accelerate, and I can still here it a cruising speeds when I hit bumps (air has to be off to hear it well)

Other than this I love the truck!

Any suggestions?

Sorry for the long post!

 

At first reading I suspected a ventilation issue. Are there any air flow issues at all when running your a/c?

 

Tim,

Thanks for your response! I dont believe it a ventilation issue because the truck runs flawlessly in the 100+ degree heat here in Louisiana. A/C has no effect on the running of the truck. The ford dealer did put chassis ears on the suspension and located a faulty upper A-arm, which they replaced (just a bad part from the factory they think). It did not fix the noise. When they attached the chassis ears to the fender, they said it lit them up. They think this could be due to the noise resonating through the frame and body, but no one has been able to pinpoint it. Hope this helps.

Thanks

 

May be a loose,or bent, hood hinge. had similar problem with a 96 f-150 that had been in a minor fender bender. hope you get this resolved,

good luck

 

Thanks, I'll check that out...I am going to take it back to the body shop that worked on it and ask them to check it out real good.

 

i don't have anything to add, other than to say you have some FANTASTIC customer service at your local ford dealer.

dealerships that offer customer service like this is few and far between.

sway bar bushings come to mind, where it mounts to the frame.

any chance you can replicate the sound by rocking/bouncing the truck from side to side? perhaps with a little help you could get under it and put your hand right on the problem.

 

No...rocking the truck side to side does not get the truck to make any noise...Ford says they could not duplicate the sound on the rack. They could only hear the sound while driving. Im at a loss on this one. I think that they did not take the suspension apart after getting it disconnected from the frame. I think they only lubricated it from the outside. It takes a lot longer to break it down off the frame and lubricate than just leave it all put together. Does that sound reasonable to anyone. This is what the body shop man is telling me...he seems very confident that the problem still lies with the bushing that sits at the top of the coil where it joins the frame.

 

Check the vacuum on your left front hub...Hell, put it in 4H and see if it goes away...

Yessir, I'm serious.