Suspension - Rear Suspension Squeak/Clunk Noise
TSB 05-10-405/30/05
SQUEAK/CLUNK NOISE FROM REAR LOWER
CONTROL ARM - VEHICLES BUILT 7/12/2004
THROUGH 9/21/2004
FORD:
2005 Five Hundred, Freestyle
MERCURY:
2005 Montego
This article supersedes TSB 05-03-02 to add a vehicle line.
ISSUE
Some 2005 Five Hundred/Freestyle/Montego FWD vehicles built 7/12/2004 through 9/21/2004 may exhibit a squeak/clunk from the rear lower control arm bushing at the subframe attachment point.
ACTION
Inspect the rear lower control arm bushing for movement between the bushing and the subframe bracket. If the bushing appears to be out of position, or movement is observed, replace the bushing with a revised part. If the bushing shows no signs of movement, use chassis ears and normal diagnostics to pinpoint the source of the noise. For bushing replacement refer to the following Service Procedure.
SERVICE PROCEDURE
1. On the side(s) of the vehicle where the bushing will be replaced, measure and write down the distance from the center of the hub to the lip of the fender with the vehicle in a level, static ground position (curb height) (Figure 1). Refer to Workshop Manual Section 204-02.
2. Raise vehicle on a hoist so the rear shock is fully extended. Refer to Workshop Manual Section 100-02.
3. Remove the tire/wheel assembly from the affected side of the vehicle.
4. Place a jack stand under the lower control arm near the attachment to outer knuckle.
5. Remove and discard the four (4) stabilizer bar-to-subframe attaching bolts and lower the stabilizer bar to gain access to lower control arm attaching bolt.
6. Remove and discard the lower control arm to subframe bolt. Some prying/manipulation of the control arm is required to remove the bolt. DO NOT PRY ON COIL SPRING.
7. Remove lower control arm bushing.
8. Insert the new knurled lower control arm bushing with the lip of the bushing facing the lower control arm nut.
9. Insert the spacer block from the Lower Arm Bushing Installer Tool (204-589) (Figure 2).
10. Position the Arm Bushing Installer Tool (204-589) over the new bushing with the small cup over the lip of the bushing (Figure 3).
11. Tighten the lead screw of the installer tool until the lower control arm bushing is pressed into position and tool cups bottom out against frame.
12. Remove the installer tool, position the lower control arm over the bushing and install a new lower control arm-to-subframe bolt. Some prying/twisting of the lower control arm will be required to install the bolt, DO NOT PRY ON COIL SPRING.
13. Before tightening the lower arm bolt, use a jack stand to raise the rear suspension until the distance between the center of the hub and the lip of the fender is equal to the measurement taken in Step 1 (curb height). Torque bolt to 92 lb-ft (125 N.m).
14. Reinstall stabilizer bar and new bolts, torque to 43 lb-ft (58 N.m).
15. Reinstall tire/wheel and tighten the wheel nuts to 95 lb-ft (129 N.m) in a star-pattern sequence.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051004A 2005 Freestyle FWD, Five 0.8 Hr.
Hundred FWD, Montego
FWD: Replace The Rear
Lower Control Arm
Bushing One Side (Do Not
Use With 5649A, 5649AT)
051004B 2005 Freestyle FWD, Five 1.1 Hrs.
Hundred FWD, Montego
FWD: Replace The Rear
Lower Control Arm
Bushing Both Sides (Do
Not Use With 5649A,
5649AT)
DEALER CODING
CONDITION
BASIC PART NO. CODE
4381 33
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