Ford Galaxy / Ford S-MAX. Manual — part 1023

Diagnosis

Wind noises often have similar causes as the general NVH noises. For instance, a windshield
which is incorrectly bonded in position can cause normal driving noises to become more
noticeable.

Asking the customer detailed questions and a road test together with the customer are the
requirements for a targeted diagnosis.

NOTE: Take the customer concern seriously. But do not confirm that a noise is a problem
until you are sure that it is something which is not normal for the vehicle series.

Possible questions:

How long has the noise been there?
Has any work been done on the vehicle?
Where does the noise come from?
In which driving situation does the noise appear?
Is there any special situation in which the noise appears?

Remember that a noise is often more or less noticeable depending on where you are sitting
in the vehicle.

Stage

to test

Result

Reference or Action

1st

Road test the vehicle with the customer. First let the

customer drive to demonstrate the noise, before you

drive the vehicle yourself. Check that the concern is

justified. Is this a noise which gives cause for concern?

Yes

Step 2.

No

Explain the noise and tell

the customer what is

causing it. Possibly offer

a comparable vehicle for

a road test.

2nd Visually inspect the vehicle. Look for loose, damaged or

missing components. Check that the vehicle is to

standard production series specification. In particular,

check for any after-market components which may

have been installed. Depending on the type of noise,

check the suspected area. Could a cause of the noise

be found?

Yes

Eliminate the noise or

carry out a repair as the

case may be. Check

whether the measures

have been successful.

No

Step 3.

3rd

Before starting any further work, use the VIN to look

for model-specific information in eTIS. Perform Oasis

query and check TSBs. Can a cause for the noise be

determined based on the information available?

Yes

Take the action specified

in the Oasis or TSB

information. Check

whether the measures

have been successful.

No

Step 4.

4th

Localize the noise. In doing so, check whether it is an

unusual noise or if it is a usual driving noise that is

more noticeable because of inadequate sealing. Is it an

Yes

Step 5.

Possible concerns with corrective measures

NOTE: Instructions on general noise are summarized separately in the Noise, Vibration
and Harshness section. These can be useful when searching for the causes of wind noises.

There follows an outline of the possible concerns relating to wind noises. Selected examples
are given showing the causes of wind noises and the ways in which they can be eliminated.
They are intended to provide troubleshooting tips and suggestions for the user but do not
represent an exhaustive faults list. The topics are subdivided by the different groups of
components.

The test procedures described in the Noise, Vibration and Harshness section can be used
when troubleshooting.

Seals

In general, seals are very important when eliminating wind noises. Special attention should
always be paid here to the possible causes of wind noises.

unusual noise?

No

Step 7.

5th

Determine the source of the noise. Can the cause be

determined?

Yes

Eliminate the noise or

carry out a repair as the

case may be. Check

whether the measures

have been successful.

No

Step 6.

6th

Determine the path of the noise using the stethoscope.

By way of a trial, mask the suspected area or

components or remove them. Can the cause be

determined?

Yes

Eliminate the noise or

carry out a repair as the

case may be. Check

whether the measures

have been successful.

No

Step 7.

7th Check the vehicle for inadequate or damaged seals. The

sealing of a vehicle can be checked using the

stethoscope, the powder test, the smoke test and the
ultrasonic detector. (See under test method.) Could a

leak be detected?

Yes

Renew the seal or

perform the appropriate

repair as necessary.

Check whether the

measures have been

successful.

No

Step 8.

8th

Under certain circumstances there may be a

constructional problem which is not yet known about.
Record the problem in an Express Service Report and

send it on by the usual method.

Take the following points into account:

Seals age, i.e. they become porous and with time they lose their original elasticity. If the
vehicle is relatively old and there are already visible signs of distortion or damage to a
seal, then it should be replaced.
At high speeds the doors or hatches may lift slightly from the seal surfaces because of
variations in air pressure. Wind noises are caused when the preload on the sealing
surface is not sufficient. The preload depends on the installation position of the
components, the elasticity of the seal and the location of the sealing flange.
The contact surface of the seal must be sufficient. This can be checked using the chalk
test. If the specifed width of the contact surface is not known, you must determine it on
another component of identical construction.
A bulging seal carrier indicates that the sheet metal of the retaining flange is uneven.
Seals must be correctly installed. Special attention must be paid at corners -arrow- that
the installation follows the contours.
The seal must not show any kinks or folds or any other damage.
Seals must seal all around their circumference. Gaps in seals result in openings which
lead to an increased incidence of noise. In this respect, it is especially important to pay
attention to the seals in the area of the windows.

Remedial Action

Renew older seals which no longer have adequate preload. Deformed or widened retaining
flanges must be reworked and provided with a new seal.

The corner areas -arrow- of a seal must be properly seated. In some circumstances, a
butyl sealing strip must be affixed to support the sealing at a corner.

Bonded joints

Glass is usually installed today using a bonded joint. Gaps in the bonded joint can lead to
noises in the vehicle interior. If there are noises which are believed to be associated with
window glass, the following points should be checked:

Gap in window bonding

The window must be bonded without any gaps -arrow-. Leaks can be found using the
ultrasonic tester or compressed air carefully blown from inside onto the window glass
bonding.
The installed position of the window glass must be correct. It must not have been bonded
into a position which is too low or offset to one side.
The sealing or trim strips must fit tightly and the glass must be mounted so that it is fully
enclosed. If a sealing or trim strip has not been applied with enough pressure, high air
speeds can cause it to lift up. This can lead to wind noises at higher speeds. Apply
masking tape to these areas for test purposes.

Corrective measures

Leaking areas of the window glass bonding material can be sealed using PU sealing
compound. Pay special attention at the front windshield, that any breaks in the bonding are
not too large. Otherwise the glass must be removed and bonded in place again.

The installed location of a window glass cannot be corrected. It must be removed and
bonded into place again.

Replace the trim strips or secure the lip seal using PU adhesive.

Gaps, edges

Door gaps and edges are places where air turbulence can form. This causes noises which
can be perceived as troublesome.

Gaps and edges - problem areas

Doors, hood and tailgate can cause wind noises because of gaps -arrow- which are too
large. If the components are not installed flush to the bodywork or the neighboring
component, air break edges can arise, which in turn can create a wind noise.

The sun roof may be the cause of whistling noises in the roof area. The sun roof may be