Fulltext TSBs

Technical Service Bulletins

TSB
10-25-3
  • CLUNK/POP NOISE HEARD/FELT UNDER FLOOR PAN WHILE TURNING – BUILT ON OR BEFORE 11/15/2010
Publication Date: December 13, 2010

FORD:
2008-2011 F-Super Duty

This article supersedes TSB 10-7-3 to add a production fix date.

ISSUE:

Some 2008-2011 F-Super Duty vehicles built on or before 11/15/2010 may exhibit a pop or clunk noise heard/felt under floor pan when turning, and may be more noticeable when cold.

ACTION:

Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

  1. Install Chassis Ear JSP97202 in Rotunda Technician Tool Program or equivalent to the right and left number 1 body support mounts located under the A-pillars.
  2. Drive the vehicle using any of the following methods to generate the noise:
    1. Approximately 20 MPH (32 Km/h) with aggressive left/right steering inputs.
    2. Approximately 10 MPH (16 Km/h) while transitioning from a flat road surface to an inclined surface.
    3. Approximately 10 MPH (16 Km/h) drive in a figure eight with steering wheel going lock-to-lock, generally an event that causes some level of frame twist and then returns to normal vehicle attitude.
  3. If a noise is heard from either or both of the number 1 body support mounts, proceed to Step 4. If noise is not isolated to either of the number 1 body support mounts, do not continue with this procedure. Use normal diagnostics. Refer to Workshop Manual (WSM), Section 501-00.

    NOTE:USE OF AIR TOOLS TO LOOSEN BODY SUPPORT MOUNT BOLTS CAN CAUSE THE CAGE NUTS TO SPIN INSIDE BODY.

  4. Use hand tools to loosen the number 1 body support mount bolt(s) from the affected side(s). Use air tools to complete removal of the bolt(s).
  5. Use a wire wheel to clean all thread lock material from the threads of the body support mount bolt(s).
  6. Apply Motorcraft® Threadlock and Sealer to the threads of the body support mount bolt(s).
  7. Reinstall the number 1 body support mount bolt(s) and torque to the high end of specification, 87 lb-ft (118 N-m).
  8. Repeat Step 2.
  9. If noise is no longer present, remove chassis ear and return vehicle to customer. If noise is still present, loosen all body support mount bolts from the affected side using hand tools except the front end sheet mount (located behind the front bumper). Use air tools to complete removal of the bolts.
  10. Use a wire wheel to clean all threadlock material from the threads of the bolts.
  11. Raise vehicle cab slightly approximately 1″ (25 mm).
  12. Install a shim between the floor pan and number 1 upper body support mount that exhibits the noise. (Figure 1)


    Figure 1 – Article 10-25-3

  13. Lower vehicle cab.
  14. Apply Motorcraft® Threadlock and Sealer to the threads of all body support mount bolts.
  15. Reinstall number 1 body support mount bolt and torque to the high end of secure specification, 87 lb-ft (118 N-m).
  16. Reinstall the remaining body support mount bolts and torque to 76 lb-ft (103 N-m).

PART NUMBERPART NAME
1C3Z-1000145-AAShim
TA-25Motorcraft® Threadlock and Sealer

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

OPERATIONDESCRIPTIONTIME
102503A2008-2011 F-Super Duty: Remove And Install Body Mount Bolt, Includes Time For Road Tests With Chassis Ear On One (1) Side (Do Not Use With Any Other Labor Operations)1.1 Hrs.
102503B2008-2011 F-Super Duty: Remove And Install Body Mount Bolts, Includes Time For Road Tests With Chassis Ear On Two (2) Sides (Do Not Use With Any Other Labor Operations)1.2 Hrs.
102503C2008-2011 F-Super Duty: Remove And Install Body Mount Bolt, Noise Still Present, Install Shim, Includes Time For Road Tests With Chassis Ear On One (1) Side (Do Not Use With Any Other Labor Operations)1.7 Hrs.
102503D2008-2011 F-Super Duty: Remove And Install Body Mount Bolts, Noise Still Present, Install Shims, Includes Time For Road Tests With Chassis Ear On Two (2) Sides (Do Not Use With Any Other Labor Operations) 2.3 Hrs.

DEALER CODING

BASIC PART NO.CONDITION CODE
100015542

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company’s on-line technical resources.

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