Clunk Grind Thump Noise from Rear of Vehicle – 2005-2006 Ford & Lincoln

CLUNK/GRIND/THUMP NOISE FROM REAR OF VEHICLE WHEN TRANSMISSION IS SHIFTED – VEHICLES BUILT BEFORE 6/13/2005

 

FORD:	2005-2006 Expedition
LINCOLN:	2005-2006 Navigator

 

2005-2006 Expedition/Navigator vehicles built before 6/13/2005, may exhibit a clunk/grind/thump noise from the rear when the transmission is shifted, during a change in vehicle direction or on acceleration.

A vibration from the driveshaft/axle area may also be exhibited.

 

ACTION:

This noise may be due to the torque arm to rear axle housing attachment bolts becoming loose.

It may be necessary to replace the four (4) attachment bolts, and the torque arm if distorted.

The torque arm attaches at the front right side of the rear differential and the #4 crossmember.

 

SERVICE PROCEDURE

1. Turn off the air suspension switch if equipped.
2. Raise vehicle.
3. Using a suitable jack-stand, support the rear axle housing.
4. Remove the four (4) torque arm to rear axle housing attachment bolts. Clean both mating surfaces.
5. Inspect the torque arm for distortion.
   1. If no distortion is found, replace only the four (4) torque arm to axle housing bolts and tighten to 150 lb-ft (200 N-m).
      1. Remove jack.
      2. Lower the vehicle.
      3. Turn on the air suspension switch if equipped.
   2. If distortion is found, replace the torque arm and the four (4) torque arm to axle housing bolts. Refer to torque arm replacement procedure.

 

TORQUE ARM REPLACEMENT PROCEDURE

1. Remove front torque arm bolt and torque arm.
2. Install the new torque arm and front bolt, do not tighten at this time.
3. Install the four (4) new torque arm to axle assembly bolts and tighten to 150 lb-ft (200 N-m).
   1. Loosen each bolt one revolution.
   2. Re-tighten each bolt to 150 lb-ft. (200 N-m).
   3. Tighten front torque arm bolt to 100 lb-ft. (135 N-m).
4. Remove jack.
5. Lower the vehicle.
6. Turn on the air suspension switch if equipped.

 

PART NUMBER	PART NAME
5L1Z-4382-A	Bolt (4 per package)
5L1Z-4612-AA	Torque Arm