Fulltext TSBs

Technical Service Bulletins

Publication Date: DECEMBER 2, 1996

1997 F-150, F-250


“Squeaking” and/or “rattling” noises may occur at different driving characteristics and from varying points on the vehicle.


To diagnose and repair squeaks and rattles, refer to the following Squeak And Rattle Summary Chart.

Figure NumberConcern DescriptionDiagnosis ProcedureRepair Procedure
1, 2, and 3Front door lock rod rattles against the lock rod grommet when going over bumps.Check for excessive play at the lock rod.Pull the door trim panel and apply flock tape to the inside of the lock rod grommet. Replace the grommet if necessary.

Figure 1 – Article 96-25-25

Figure 2 – Article 96-25-25

Figure 3 – Article 96-25-25

Figure NumberConcern DescriptionDiagnosis ProcedureRepair Procedure
4 and 5The underside of the front door watershield contacts the lock rod causing a squeak when the lock is actuated (vehicles built prior to 2/12/96).Pull the door trim panel to see if the “sticky” side of the watershield is making contact with the lock rod.Cut the watershield at the bottom of the lock rod slit. Cut 12.7mm (1/2″) horizontally and then 12.7mm (1/2″) vertically to create a flap that fits behind the lock rod.

Figure 4 – Article 96-25-25

Figure 5 – Article 96-25-25

Figure NumberConcern DescriptionDiagnosis ProcedureRepair Procedure
6Door trim panel rattle occurs during dynamic drives and static door closings.Listen for door trim panel flutter when closing door while seated in vehicle.Add flock tape to the MN-12 clips on the bottom of the door trim panel to tighten fit with door inner.
 Door check strap creaking/popping noise during door actuation.Open the cab door and listen for creaking/popping.Apply Teflon-based lubricant to the clevis joint (bracket at door). If Teflon-based lubricant does not work, then change the check strap.

Figure 6 – Article 96-25-25

Figure NumberConcern DescriptionDiagnosis ProcedureRepair Procedure
7Hood latch cable rattle under the left side of the instrument panel. Rattle may be internal (cable against surrounding components).Dampen the cable by tie-strapping it to the -14401- wire bundle at the LH cowl side.Same as Diagnosis.
 RH side instrument panel rattle due to the -14401- heater take-out wire contacting the plastic warranty book pocket.Check for contact between the -14401- heater take-out and the warranty pocket (refer to 1997 F-150-250 Electrical and Vacuum Troubleshooting Manual (EVTM) 151-10, C210).Reroute heater take-out wire or apply foam tape to affected area of the warranty book pocket.
 LH Side instrument panel (I/P) squeak/tick due to plastic instrument panel components rubbing against one another. May be intermittent and temperature sensitive.Inspect steering column upper cover panel, fuse box cover, and lower I/P cover for witness marks. May also be able to duplicate noise by pressing on the panels at various locations (refer to 1997 F-150-250 Workshop Manual, Page 501-12-2 for diagram).Apply flock tape or mylar to all areas where components touch, especially those surfaces that are painted and stressed.
 Glove compartment door rattles when driving over hard bumps.Empty the glove compartment and drive the unit over hard bumps.Adjust the glove compartment door striker forward to tighten the fit. Add flock tape to hinge surfaces. Add foam tape to the glove compartment door opening to dampen the rattle.
 Steering wheel clockspring scrubbing noise when turning.Turn the steering wheel and listen for a low, scratchy scrubbing noise.Remove the air bag from the steering wheel and verify that the clockspring is seated/neutralized by pressing on the clockspring at the 12, 6, and 3 o’clock positions. If the noise is present after checking the positions, back off the nut securing the wheel to the steering column allowing the clockspring to relax/neutralize. If the noise is still present, back off the nut securing the steering wheel to the column. Remove the steering wheel and then remove the service lock (“T” shaped metal spring from the top of the clockspring). Reassemble the steering wheel, torquing the nut and installing the air bag in reference to the 1997 F-150-250 Workshop Manual, Section 211-04.
 Rubbing noise at the left front wheel. The left front tire rubs against the block fitting on the brake line assembly (4X2 non-ABS units).Inspect the left front brake block bracket for deformation.Gently bend the brake block bracket inboard to its design position.
 Underhood rattle caused by the 4.6L throttle body cover (snow shield) contacting the air bypass resonator.Tap on the driver’s side of the throttle body cover and listen for rattle.Remove the throttle body cover and apply a piece of foam adhesive to the top-forward edge of the air bypass resonator. The foam strip should be approximately 38x76x9mm (1.5″x3″x0.375″) thick and should be made of neoprene sponge, EDPM sponge, or close cell urethane. Reassemble the throttle body cover.
 Underhood rattle due to the transmission fill tube rattling against the A/C canister on 4.2L and 4.6L engines.Visually inspect for contact between the fill tube and the A/C canister (dryer). The fill tube should be centered between the canister and the engine.Check that the fill tube is properly secured to the transmission housing. If it is properly secured and still making contact, gently bend the fill tube away from the A/C canister.
 Underhood rattle on 4.6L engines due to accelerator cable contacting the power steering reservoir bracket (vehicles built prior to 3/11/96).Check that the accelerator cable is routed properly or otherwise coming into contact with the reservoir bracket without a foam interface.Reroute the cable if not routed properly. Wrap foam tape around the cable where it comes into contact with the metal bracket (3/11/96 production date fix).
 Perceived instrument panel squeak going over bumps due to the engine fuel line bracket rubbing against the cowl.Check for metal-to-metal contact between the engine fuel line bracket (located at the rear of the engine) and the cowl.Bend the fuel line bracket forward 5-10 degrees to prevent contact with the cowl.
 60% rear seat buckle rattle.Check for looseness of individual seat buckles.Add flock/foam tape between the buckles to dampen movement.
 Perceived instrument panel ticking noise due to the slip/stick motion between the bottom edge of the windshield and the glass top.Remove the leaf screen and push either end of the windshield glass stop to simulate the concern.Remove the windshield glass stop and reassemble the leaf screen.
 Sliding back glass buzz.Listen for a rattle in the sliding back glass due to fore/aft movement in the glass channel.Add flock tape to the backside of the bottom glass channel to tighten the fit.
 Rear underbody creaking/popping noise due to the “T” end of the front fuel tank strap rubbing the frame rail.Listen for noise during frame twisting such as driving up on a curb or a hard LH turn. The noise can also be induced by pushing at the rear of the box in a side-to-side motion or by wedging a screwdriver into the joint at the “T” end of the front fuel tank strap.Loosen the front fuel tank strap. Place a 76x76x3mm (3″x3″x1/8″) thick butyl patch in the outboard bend of the strap. Reassemble the strap and torque the attaching bolt to 35 ±5.3 N-m (26 ±4 lb-ft).
 Underbody rattle due to the HEGO sensor connector rattling against the underside of the floor pan on 4X4 units.The HEGO sensor connector is located above the transfer case. Check for contact with the floor pan.Reorient the HEGO sensor connector in the bracket or provide an interface with foam tape.

Figure 7 – Article 96-25-25

Figure NumberConcern DescriptionDiagnosis ProcedureRepair Procedure
8Rear underbody rattle with a low, hollow tone caused by slapping of the rear leaf springs.Check for noise at slower speeds.Gap the springs and add a foam pad insulator on the spring inserts.
 Rear underbody rattle occurs when vehicle travels over hard bumps and when the tailgate is dropped.The heat shield is located toward the front of the box above the exhaust. Check for contact between the box heat shield and the frame.Bend the edge of the heat shield away from the frame with a screwdriver.

Figure 8 – Article 96-25-25




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Copyright © 1996 Ford Motor Company