Air Ride Rattle

[hafcanadian]

Our '97 Explorer Limited developed a rattle several years ago. It only did it in warm, dry weather. Our local mechanic finally heard it, after several rides trying to get it to do it (that never happens, right?). He gave the rig back to me, no charge for his time, and said he thought it was the air ride level sensor device behind the driver's front wheel.

Today I finally got around to removing the wheel so I could see better what he was referring to. Yes, the device "rattles" from where an apparent rod meets a tube. But it's inside a protective bellows-like sleeve that's fastened top and bottom with special crimped clamps I dare not try to remove. I am amazed that the minimalist rattling heard at the device is amplified into the passenger compartment and is even felt in the steering wheel. But apparently that's so.

I could see no way to stop the annoying noise other than to use a wire tie around a nearby brake tube mount to see if it will mitigate the "slop" between the rod and tube. Of course "rod and tube" are just assumptions on my part since I can't remove the rubber sleeve surrounding those components. I've yet to test drive my "fix", and am wondering if anyone else here has dealt with this issue. Please advise if the wire tie might cause issues; I did not tighten it, but rather used it to merely move the upper sensor box enough to take up a smidge of its slop... about 1/16th inch... and hopefully not cause any binding rod into tube. Any thoughts or experience would be appreciated.

 

[Fix4Dirt]

Our '97 Explorer Limited developed a rattle several years ago. It only did it in warm, dry weather. Our local mechanic finally heard it, after several rides trying to get it to do it (that never happens, right?). He gave the rig back to me, no charge for his time, and said he thought it was the air ride level sensor device behind the driver's front wheel.

Today I finally got around to removing the wheel so I could see better what he was referring to. Yes, the device "rattles" from where an apparent rod meets a tube. But it's inside a protective bellows-like sleeve that's fastened top and bottom with special crimped clamps I dare not try to remove. I am amazed that the minimalist rattling heard at the device is amplified into the passenger compartment and is even felt in the steering wheel. But apparently that's so.

I could see no way to stop the annoying noise other than to use a wire tie around a nearby brake tube mount to see if it will mitigate the "slop" between the rod and tube. Of course "rod and tube" are just assumptions on my part since I can't remove the rubber sleeve surrounding those components. I've yet to test drive my "fix", and am wondering if anyone else here has dealt with this issue. Please advise if the wire tie might cause issues; I did not tighten it, but rather used it to merely move the upper sensor box enough to take up a smidge of its slop... about 1/16th inch... and hopefully not cause any binding rod into tube. Any thoughts or experience would be appreciated.

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imo the fix is fine, but i personally have no experience with the ARC system

 

[CDW6212R]

Welcome, and wow, I'm amazed that anyone still has an intact ARC system, any version.

I bought the entire set of parts and wiring from a 98 Limited and installed everything but the original shocks and front sensors/lines, and made mine a rear leveling only system(1999-2001).

The height sensors are not weak links, other than the end ball/joint connections. Those need to be lubricated regularly so that the steel ball end doesn't rust away. As it rusts, gets smaller, that creates slop there which will affect the ride height variably(as it goes to the top or bottom of range).

The real weak links are the air line connections, all of them, which when they leak it forces the compressor to run constantly(which will kill it). So check all air line connections, and replace as needed the plastic or rubber o-rings depending on which is there. The air solenoids you can remove to work on those connections, the ARC shocks are harder to deal with because the shock itself is rare and old ones are worn out. The rear shocks are still easy to come by, eBay or RA etc, the front are very hard to get, and high dollar.

Here's my refurbished ARC compressor before I installed it in 2006. I had to fabricate new rubber mounts, the OEM type sucked.

 

[hafcanadian]

Thanks. I didn't know it was called ARC. I did find out the hard way a few years ago that it has to be dealt with properly by tire installers. And it was at a Ford dealer, no less. They put new tires on the front (towing behind a motor coach seems to throw off the alignment), and didn't shut off the system at its switch in the back cargo area. I guess it has to be done at the right time relative to the car going on the lift. When I left the dealership it didn't ride right... stiff as a board. I immediately returned and the after hours service manager and I diligently worked at figuring out the problem. He finally got the right sequence of switch ON/OFF and driving to get the air working again. Don't ask me... I still don't know how we got it to work! I just hope it doesn't happen again.

Reckon I'll have to look under the hood for a pump anything like your photo. I never paid any heed to where it was or looked like. Our coach has an HWH air ride system, and associated leveling system, but uses an engine driven pump and 2 tanks that supply other devices as well, including the brakes.

A 4 mile drive yesterday revealed mitigated but not eliminated rattling. So I'm not totally convinced the rattle is all from that sensor. I can even feel it in the steering wheel, and it's louder inside while driving compared to when I remove the tire/wheel and directly jiggle the sensor. The mechanic thinks the logistics of all things metal amplifies the movement into a more audible (and apparently feelable) rattle inside. I need to have someone jiggle it I reckon while I'm sitting in the drivers seat.

Maybe I'll try cinching up the wire tie a smidge more, but I don't want to risk messing up the sensor's intent.

 

[CDW6212R]

That ARC compressor is mounted right above the spare tire, on top of that cross member part. Keep an ear out for that running to much, which would point to an air leak that is too large. You might have someone spray the air line connections once a year to see how much they leak air. There's an air line connection at each shock, and the compressor air reservoir, and the solenoids nearby back there.

For the ARC on/off switch, just turn it off whenever you need to lift the rear tires off the ground or jack up the body back there at all. That way it won't adjust the air in the shocks until you turn it back on.

There are lots of things which could make noise in the front. I'd inspect a lot of parts up there for any looseness or any reason to replace something. The ride height would be kind of at the bottom of a list I might make for causing a noise. Hopefully it's something else and easier to deal with.

 

[hafcanadian]

That ARC compressor is mounted right above the spare tire, on top of that cross member part. Keep an ear out for that running to much, which would point to an air leak that is too large. You might have someone spray the air line connections once a year to see how much they leak air. There's an air line connection at each shock, and the compressor air reservoir, and the solenoids nearby back there.

For the ARC on/off switch, just turn it off whenever you need to lift the rear tires off the ground or jack up the body back there at all. That way it won't adjust the air in the shocks until you turn it back on.

There are lots of things which could make noise in the front. I'd inspect a lot of parts up there for any looseness or any reason to replace something. The ride height would be kind of at the bottom of a list I might make for causing a noise. Hopefully it's something else and easier to deal with.

Okay, I recall that now, and can probably remember for the next time the car goes on a lift somewhere. There has never been a leak in the car's system, but the height sensor(s) have come up out of position from missing and broken mounting bolts or screws at least once, causing the front of the car to lean to one side just barely noticeably. I was told some years ago that the or a sensor had one missing bolt and a second loose one, but not according to what I'm looking at now; in fact the top mount only uses one fastener. Perhaps there's another sensor somewhere else?

As an aside, how does one change the profile image on this Forum? I've looked for instructions, right-clicked on the big green "H" in my signature/profile, as per most other forums, but nothing works other than to add a "cover photo", whatever that's for.

 

[Fix4Dirt]

Okay, I recall that now, and can probably remember for the next time the car goes on a lift somewhere. There has never been a leak in the car's system, but the height sensor(s) have come up out of position from missing and broken mounting bolts or screws at least once, causing the front of the car to lean to one side just barely noticeably. I was told some years ago that the or a sensor had one missing bolt and a second loose one, but not according to what I'm looking at now; in fact the top mount only uses one fastener. Perhaps there's another sensor somewhere else?

As an aside, how does one change the profile image on this Forum? I've looked for instructions, right-clicked on the big green "H" in my signature/profile, as per most other forums, but nothing works other than to add a "cover photo", whatever that's for.

iirc to add an avatar have to be elite

 

[hafcanadian]

Well, we took a 30 mile drive to appointments and shopping yesterday and the confounded rattle is worse than ever. I'll try cinching the wire tie a bit more, but it's still hard to believe the rattle is coming from that sensor. It clunks with even the slightest move of the car, rattles incessantly on the road, and I swear I can feel it through the steering wheel. But it won't do it during the winter here in western Oregon or anytime the weather isn't dry. The heat wave here now must be exacerbating it.