Pop/Clunk/Snap Noise From The Rear Of Vehicle When Driving Up/Down An Incline At An Angle

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NHTSA ID Number: 10215718

Manufacturer Communication Number: TSB 22-2283

Summary

This article supersedes TSB 21-2253 to update the vehicle lines affected. Some 2021 F-150 (non-Raptor/non-Tremor) vehicles with rear gross axle weight rating (GAWR) of 1542 kg (3,400 lb) or 1724 kg (3,800 lb) shown on the vehicle certification (VC) label may experience a pop/clunk/snap noise from the rear of vehicle when driving up/down an incline at an angle (frame twist). This approach angle would be similar to entering or leaving a driveway. This may be due to movement between the rear spring and the rear spring mounting plate on the rear axle. To correct the condition, follow the Service Procedure to apply lubrication between the rear spring and the rear spring mounting plate mating surfaces on the rear axle.

This bulletin supersedes 21-2253.

Model:

Ford

2021 F-150
non-Raptor
non-Tremor

Summary

This article supersedes TSB 21-2253 to update the vehicle lines affected.

Issue: Some 2021 F-150 (non-Raptor/non-Tremor) vehicles with rear gross axle weight rating (GAWR) of 1542 kg (3,400 lb) or 1724 kg (3,800 lb) shown on the vehicle certification (VC) label may experience a pop/clunk/snap noise from the rear of vehicle when driving up/down an incline at an angle (frame twist). This approach angle would be similar to entering or leaving a driveway. This may be due to movement between the rear spring and the rear spring mounting plate on the rear axle. To correct the condition, follow the Service Procedure to apply lubrication between the rear spring and the rear spring mounting plate mating surfaces on the rear axle.

Action: Follow the Service Procedure to correct the condition if the vehicle meets all of the following criteria:

2021 F-150 (non-Raptor/non-Tremor)

Rear GAWR of 1542 kg (3,400 lb) or 1724 kg (3,800 lb) shown on the VC label

Pop/clunk/snap noise from the rear of vehicle when driving up/down an incline at an angle (frame twist)

Parts

Service Part Number	Quantity	Description	Unit of Issue	Piece Quantity
ML3Z-5705-A	4	U-bolt (4×2 Only)	1	4
ML3Z-5705-B	4	U-bolt (4×4 Only)	1	4
W520215-S441	2	U-bolt Nut	4	8
W506545-S439	1	Shock Bolt	4	2
W520214-S440	1	Shock Nut	4	2
XG-1-E1	As Needed	Motorcraft® Premium Long-Life Grease

Quantity refers to the amount of the service part number required to repair the vehicle.

Unit of Issue refers to the number of individual pieces included in a service part number package.

Piece Quantity refers to the total number of individual pieces required to repair the vehicle.

As Needed indicates the amount of the part may vary and/or is not a whole number. Parts can be billed out as non-whole numbers, including less than 1.

Service Procedure

1. Check the rear GAWR found on the VC label. Refer to Workshop Manual (WSM) Section 100-01. Is the rear GAWR 1542 kg (3,400 lb) or 1724 kg (3,800 lb)?

(1). Yes – proceed to Step 2.

(2). No – this article does not apply. Refer to WSM, Section 100-04 for normal diagnostics.

2. Position the vehicle on a hoist. Refer to WSM, Section 100-02.

3. Support the axle assembly on both sides with a transmission jack.

NOTE: Perform the following steps one side at a time.

4. Remove and discard the rear shock absorber lower nut and bolt.

5. Remove and discard the rear spring U-bolts and U-bolt nuts.

6. Lower the transmission jack 5-7.5 cm (2-3 inches) to allow the rear axle assembly to separate from the rear spring.

NOTE: On 4X4 equipped vehicles, make sure to note the correct orientation of spring spacer before removal. Refer to WSM, Section 204-02 > Spring Installation > Step 1 for information about spring spacer orientation based on the vehicle’s wheelbase. Failure to properly install the spring spacer could lead to noise vibration and harshness (NVH) related issues.

7. Clean any debris from the mating surfaces between the rear spring and the rear spring mounting plate on the rear axle. If equipped with four-wheel drive (4WD), mating surfaces for the spring spacer will also need to be cleaned of any debris. (Figure 1)

8. Apply a thin layer of Motorcraft® Premium Long-Life Grease to the bottom surface of the rear spring.

9. Raise the rear axle assembly and install new U-bolts and new U-bolt nuts and tighten the U-bolt nuts in a cross pattern in 4 stages.

(1). Stage 1: Tighten to 40 Nm (30 lb-ft)

(2). Stage 2: Tighten to 80 Nm (59 lb-ft)

(3). Stage 3: Tighten to 120 Nm (89 lb-ft)

(4). Stage 4: Tighten to 150 Nm (111 lb-ft)

10. Install the new rear shock absorber lower nut and bolt and tighten to 90 Nm (66 lb-ft).

11. Lower the transmission jack and remove the vehicle from hoist.

1 Affected Product

Vehicle

MAKE	MODEL	YEAR

FORD	F-150	2021

1 Associated Document

Manufacturer Communications

22-2283
12 July 2022

https://www.nhtsa.gov/recalls?nhtsaId=10215718

MC-10215718-0001.pdf 107.628KB

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NHTSA ID Number: 10201613

Manufacturer Communication Number: TSB 21-2253

Summary

Some 2021 F-150 vehicles with rear gross axle weight rating (GAWR) of 1542 kg (3,400 lb) or 1724 kg (3,800 lb) shown on the vehicle certification (VC) label may experience a pop/clunk/snap noise from the rear of vehicle when driving up/down an incline at an angle (frame twist). This approach angle would be similar to entering or leaving a driveway. This may be due to movement between the rear spring and the rear spring mounting plate on the rear axle. To correct the condition, follow the Service Procedure to apply lubrication between the rear spring and the rear spring mounting plate mating surfaces on the rear axle.

1 Associated Document

Manufacturer Communications

21-2253
01 September 2021

https://www.nhtsa.gov/recalls?nhtsaId=10201613

MC-10201613-0001.pdf 107.737KB

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