Rattle from front right wheel area - not A Pillar

dco43054 · July 7, 2012

So, I've noticed a pronounced rattle from the right side, front, when driving over a bump or rough surface. It is nowhere near the A pillar. it is only when the right side of the vehicle goes over rough surfaces. It does not happen with the left side.

I first thought loose suspension component. Just jacked it up, and took a long look at all the mounting points, looked for obvious signs of loose componenets (scratches, bright scrapes, gaps, etc) and nothing.

So I looked at the upper end of the strut mount and nothing. Then I started wiggling stuff in the engine compartment in that area, and the first thing I laid my hands on, the radiator reservoir, is obviously loose. It has two bolts and a slip in mount in the one corner that hold it in place. The slip in mount is not tight at all and the reservoir will rattle against the body.

I guess it could be that easy, but I wouldn't think so. The sound I am getting is more like a suspension rattle, but the reservoir is hollow, so it could be the source. I am going to put a piece of inner tube behind it just to tighten the fit and eliminate it, or identify it, as the source of the rattle.

Anyone else had a similar rattle?

dco43054 · July 7, 2012

Yeah, no such luck on the reservoir. I didn't think it would be anything so easy. The noise wasn't right, anyhow. Oh well, I will hunt a little longer, then it's off to the dealer to have them figure it out.

dco43054 · April 20, 2013

Finally found the source. It was a bad ball joint on the end of the strut that connects the front sway bar to the top of the suspension strut.

I could have had the dealer do this, but it was just easier to do myself. The part was under $30. It took longer to jack the vehicle up/down and remove/replace the wheel than to unbolt the part and bolt the new one in. I was able to use my impact on the top mount, but had to use a wrench on the bottom. The nuts are 22mm, and the ends of the ball joints have a 10mm hex to keep the ball joint from spinning while removing/replacing the nut.

Here's the part. The lower ball joint had a bout a 1/4" of travel in it. Manufacturing defect.

1995E · April 20, 2013

This isn't the first case of something going wrong with the suspension for the new Explorers. How many miles have you had on it?

R1chard · April 20, 2013

The past week or so I've been experiencing this subtle "rattle" (like something is loose) sound from the left side suspension which sounds exactly like what you described.

The noise is only there during small imperfections on the road at city driving / rolling speeds however it has been getting ever so more pronounced and slightly louder just during this past week.

Come Monday morning I will give my Ford dealer a call to have them inspect the the ball joints and try to further diagnose the problem.

My Explorer is a 2013 4WD Limited with 3400 miles on it.

dco43054 · April 20, 2013

1995E said:
This isn't the first case of something going wrong with the suspension for the new Explorers. How many miles have you had on it?

The noise started at around 25,000 miles. I now have 40,000. It has been getting progressively worse. I checked the steering ball joints periodically and they were fine. I thought that was the likely cause of the problem.

These are on the link between the sway bar and the top of the strut tower.

FordService · April 24, 2013

R1chard said:
The past week or so I've been experiencing this subtle "rattle" (like something is loose) sound from the left side suspension which sounds exactly like what you described.

The noise is only there during small imperfections on the road at city driving / rolling speeds however it has been getting ever so more pronounced and slightly louder just during this past week.

Come Monday morning I will give my Ford dealer a call to have them inspect the the ball joints and try to further diagnose the problem.

My Explorer is a 2013 4WD Limited with 3400 miles on it.

Hi R1chard,

How are things going with your Explorer? Have you had the chance to take it by your dealership? I can step in here and assist as well; just send me a PM with your VIN, dealer, mileage, daytime phone number, and full name. I'll get to work on your case.

Crystal

R1chard · April 25, 2013

FordCustSrvc said:
Hi R1chard,

How are things going with your Explorer? Have you had the chance to take it by your dealership? I can step in here and assist as well; just send me a PM with your VIN, dealer, mileage, daytime phone number, and full name. I'll get to work on your case.

Crystal

Crystal, I did in fact take the car to the dealer on Tuesday AM. Initially the tech could not reproduce/notice the noise and they asked me to drive around the block with him and point it out once it happened. Within a few minutes of driving I pointed out the noise and the tech said along the lines "that noise! I hear that and it should not be".

They placed the Explorer back on the lift and about 25 minutes later they come out to tell me they will need to replace the driver's side strut assembly and parts are on order. They were as perplexed as myself as to such premature failure on a brand new vehicle with <4K miles.

That's where I stand right now, awaiting for a call back as to when the parts arrive to the dealer. In the meantime the noise seems to be getting louder / more prominent during city driving which is making me unsure about driving the vehicle though the dealer cleared it for me to use it until the repair occurs.

I'm going to call the dealer back tomorrow AM and see where we stand.
Crystal, if there is no plan of action with that call then I will be contacting you for more pressing assistance on your side.

Thanks!
Richard

Azazell64 · April 25, 2013

These sway bar end links are famous for going wrong and making horrific noises. The early 2000's F-150's had a problem with them wearing out prematurely. I've replaced several sets.

dco43054 · April 26, 2013

Azazell64 said:
These sway bar end links are famous for going wrong and making horrific noises. The early 2000's F-150's had a problem with them wearing out prematurely. I've replaced several sets.

It is amazing the amount of noise it makes for such a little ball joint. I thought I had some major suspension member that was loose. I went around shaking wheels, looking everywhere - except obviously there, until a week ago.

Really simple fix, thankfully.

converted_21 · April 26, 2013

My sport makes a strange noise from the front passenger suspension when going over spend bumps, dips or rough surfaces. Only at 1,500 miles so too soon to pin point what it is.

Azazell64 · April 26, 2013

I have actually seen these end links be broken in half on the shaft portion on a couple vehicles. Others, like you say, are just worn out joints.

dco43054 · April 27, 2013

converted_21 said:
My sport makes a strange noise from the front passenger suspension when going over spend bumps, dips or rough surfaces. Only at 1,500 miles so too soon to pin point what it is.

Too soon?

Take it to the dealer. Make sure they check out the sway bar links.

FordService · April 29, 2013

R1chard said:
...Crystal, if there is no plan of action with that call then I will be contacting you for more pressing assistance on your side.

Thanks!
Richard

Hi Richard,

I wanted to touch base with you and see how things are going with your Explorer. If you need additional assistance from me, I'm just a few mouse clicks away.

Crystal

R1chard · April 29, 2013

Crystal, I dropped off my car today 0730AM and had it back by 1030AM with issued addressed.

The dealer ended up replacing "a bearing located on the top of the driver side strut" that seemed to be defective upon inspection. The car no longer experiences the rattle and feels like it before.

Very happy that this was addressed quickly and efficiently. :thumbsup:

Thank you for the follow up.
Richard

FordService · April 30, 2013

R1chard said:
Crystal, I dropped off my car today 0730AM and had it back by 1030AM with issued addressed.

The dealer ended up replacing "a bearing located on the top of the driver side strut" that seemed to be defective upon inspection. The car no longer experiences the rattle and feels like it before.

Very happy that this was addressed quickly and efficiently.

Thank you for the follow up.
Richard

This is great news, Richard! Thank you for sharing your outcome with everyone.

Crystal

R1chard · April 30, 2013

Unfortunately today after a more extensive driving session the noise has returned, though not as pronounced as before (at least not yet).

Crystal, I sent you a message with the previously requested information as well as more details.

Best,
Richard

FordService · May 1, 2013

R1chard said:
Unfortunately today after a more extensive driving session the noise has returned, though not as pronounced as before (at least not yet).

Crystal, I sent you a message with the previously requested information as well as more details.

Best,
Richard

Hi Richard,

I responded to your message with your escalation information. Let me know if you have any questions.

Crystal

converted_21 · May 1, 2013

I'm just curious, on my Sport it makes horrible squeaking and rubbing noises from the front when going over dips and speed bumps... Is that anything that anyone else experiences?

Smash2723 · May 1, 2013

I am having the same issue, but it is just a chattering noise(no squeaking or rubbing) that is getting progressively worse and seems to be from the right side when going over rough pavement/bumps. It's to the point where you can feel the rattling now. I'm curious to hear people's results with this, if anyone else has had the same problem, as I think it will be helpful when bringing it in and asking for warranty service.

Rattle from front right wheel area - not A Pillar

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