Pop Or Creak Noise From Right Front Mounting Bolt Of Front Subframe

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BODY CREAK/POP NOISE OVER BUMPS – RIGHT FRONT SUBFRAME BOLT AREA – BUILT ON OR BEFORE 1/31/2016

ISSUE:

Some 2016 Explorer vehicles built on or before 1/31/2016 may exhibit a pop or creak noise from the right front mounting bolt of the front subframe.

This condition may be due to a mispositioned weld between the barrel nut and the subframe mounting bracket.

Follow the Service Procedure steps to correct the condition.

The steps below will add an additional weld to eliminate the possibility of the barrel nut creak/pop noise.

Attach Rotunda Wireless Chassis Ears JSP97202 or equivalent. Does diagnosis with chassis ears indicate the noise is originating from the right front mounting bolt of the front subframe?
1. Yes – proceed to Step 2.
1. No – this article does not apply. Refer to Workshop Manual (WSM), Section 100-04 for normal diagnostics.

Locate the front subframe bolt mounting tower bracket on the right side frame member and mark 2 cut lines approximately 63 mm (2.50 in) long as shown. (Figure 1)

Figure 1

Using an abrasive cut off wheel, cut the bracket sheet metal along the marked lines. (Figure 2)
1. Make sure to only cut through the outer layer.

Figure 2

Position the sheet metal out of the way to allow access to the barrel nut. (Figure 3)

Figure 3

Using a MIG welder, weld the barrel nut to the bracket along the seam. The weld bead should span as far along the seam as possible. (Figure 4)

Figure 4

Using a MIG welder, weld the previously cut sheet metal to repair the bracket. (Figure 5)

Figure 5

Apply ValuGard Premium Undercoating, or equivalent corrosion protection to the repaired cut line area. Refer to WSM, Section 501-25. (Figure 6)

Figure 6

Apply ValuGard Rust Inhibitor, or equivalent to the welded barrel nut. Refer to WSM, Section 501-25.
1. Use an appropriate spray nozzle to access the cavity. (Figure 7)

Figure 7