Ford Falcon. Manual — part 16
100-04-36
Noise, Vibration and Harshness
100-04-36
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST A : BRAKE VIBRATION/SHUDDER
Test Step
Result / Action to Take
A1
ROAD TEST THE VEHICLE—LIGHT BRAKING
Check that the wheel and tyres are correct for the vehicle. Inspect the
Yes
tyres for abnormal wear patterns.
Go to A4.
Road test the vehicle. Warm the brakes by slowing the vehicle a few
No
times from 80–32 km/h (50 to 20 mph) using light braking
Go to A2.
applications. At highway speeds of 89–97 km/h (55-60 mph), apply
the brake using a light pedal force.
Is there a vibration/shudder felt in the steering wheel, seat or
brake pedal?
A2
ROAD TEST THE VEHICLE—MODERATE TO HEAVY
BRAKING
Road test the vehicle. At highway speeds of 89–97 km/h (55-60 mph),
Yes
apply the brake using a moderate to heavy pedal force.
For vehicles with ABS, Go to A3.
For vehicles with standard brakes, Go to A4.
Is there a vibration/shudder?
No
Vehicle is OK. VERIFY condition with customer.
TEST the vehicle for normal operation.
A3
NORMAL ACTUATION OF THE ABS SYSTEM
DIAGNOSIS
During moderate to heavy braking, noise from the hydraulic control
Yes
unit (HCU) and pulsation in the brake pedal can be observed. Pedal
Go to A5.
pulsation coupled with noise during heavy braking or on loose gravel,
No
bumps, wet or snowy surfaces is acceptable and indicates correct
The brake system is operating correctly.
functioning of the ABS system. Pedal pulsation or steering wheel
nibble whose frequency is proportioned to the vehicle speed indicates
a concern with a brake or suspension component.
Is the vibration/shudder vehicle speed sensitive?
A4
APPLICATION OF THE PARKING BRAKE
Yes
NOTE:
Begin at the front of the vehicle unless the vibration or shudder
Go to A8.
has been isolated to the rear.
No
This test is not applicable to vehicles with drum-in-hat type parking
Go to A5.
brakes. For vehicles with drum-in-hat parking brakes, proceed to the
next test. For all other vehicles, apply the parking brake to identify if
the problem is in the front or rear brake. At highway speeds of 89–97
km/h (55-60 mph), lightly apply the parking brake until the vehicle
slows down. Release the parking brake immediately after the test.
Is there a vibration/shudder?
A5
CHECK THE FRONT WHEEL BEARINGS
Check the front wheel bearings. Refer to Wheel Bearing Check in this
Yes
section.
Go to A6.
Are the wheel bearings OK?
No
INSPECT the wheel bearings. ADJUST or
REPAIR as necessary. TEST the system for
normal operation.
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100-04-37
Noise, Vibration and Harshness
100-04-37
DIAGNOSIS AND TESTING (Continued)
Test Step
Result / Action to Take
A6
CHECK THE FRONT SUSPENSION
Check the front suspension for:
Yes
Go to A7.
broken or loose bolts
damaged springs
No
REPAIR or INSTALL new components as
worn or damaged lower control arm bushings
necessary. TEST the system for normal
loose or rough front bearings
operation.
uneven tyre wear
Are all the suspension components in satisfactory condition?
A7
RESURFACE THE FRONT BRAKE DISCS
Yes
CAUTION:
Do not use a bench lathe to machine brake discs.
Go to A8.
NOTE:
Follow the manufacturer’s instructions to machine the brake
No
discs. After machining, make sure the brake disc meets the thickness
Vehicle is OK.
specification.
Refer to Brake Disc Machining in this section. Resurface the front
brake discs. Road test the vehicle.
Is the vibration/shudder present?
A8
CHECK THE REAR SUSPENSION
Check the rear suspension for:
Yes
Go to A9.
broken or loose bolts
damaged or worn springs or spring bushings
No
REPAIR or INSTALL new components as
worn or damaged upper and lower control arm bushings
necessary. TEST the system for normal
worn or damaged trailing arms
operation.
loose or rough rear bearings
uneven tyre wear
Are all the suspension components in satisfactory condition?
A9
RESURFACE THE REAR BRAKE DISC OR DRUM
Yes
CAUTION:
Do not use a bench lathe to machine brake discs.
CHECK the front suspension for wear or
damage, RESURFACE the front brake discs.
NOTE:
Follow the manufacturers instructions to machine the brake discs. TEST the system for normal operation.
After machining, make sure the brake disc meets the thickness
specification.
No
Vehicle is OK.
Refer to Brake Disc Machining in this section. Resurface the rear
brake disc or drums. Road test the vehicle.
Is the vibration/shudder present?
PINPOINT TEST B : ENGINE TICKING NOISE
Test Step
Result / Action to Take
B1
CHECK FOR TICKING NOISE AT THE FUEL RAIL
Disconnect the first fuel line clip.
Yes
CHECK for TSB for applicable vehicle. REPAIR
Is the ticking noise gone?
as necessary. TEST the system for normal
operation.
No
Go to B2.
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100-04-38
Noise, Vibration and Harshness
100-04-38
DIAGNOSIS AND TESTING (Continued)
Test Step
Result / Action to Take
B2
CHECK FOR TICKING NOISE AT THE FUEL INJECTOR
Using an EngineEAR, listen at the fuel injectors by placing a probe on
Yes
each injector. To isolate the faulty injector, disconnect the injector
INSTALL a new fuel injector. REFER to Section
electrical connector and listen for the noise.
303-04a for 2.0L Zetec engine or Section
303-04b for 3.0L (4V) engine. TEST the system
Is the fuel injector the source of the ticking noise?
for normal operation.
No
Go to B3.
B3
CHECK THE BELT TENSIONER FOR TICKING NOISE
Inspect the front engine accessory drive (FEAD). Check for the belt
Yes
tensioner bottoming at end of travel or not at end of stroke.
INSTALL a new belt tensioner. REFER to
Section 303-05 . TEST the system for normal
Using an EngineEAR, listen at the belt tensioner.
operation.
Is the belt tensioner the source of the noise?
No
Go to B4.
B4
CHECK THE WATER PUMP FOR TICKING NOISE
Using an EngineEAR, listen at the water pump for ticking noise.
Yes
INSTALL a new water pump. REFER to Section
Is the water pump the source of the noise?
303-03 . TEST the system for normal operation.
No
Go to B5.
B5
CHECK FOR AN OBSTRUCTION OF THE COOLING FAN
Inspect the cooling fan for obstructions.
Yes
REPAIR or INSTALL a new cooling fan. REFER
Check the cooling fan and shroud for wear or damage.
to Section 303-03 . TEST the system for normal
operation.
Was there an obstruction or does the cooling fan show signs of
damage?
No
Go to B6.
B6
CHECK THE OIL PUMP FOR TICKING NOISE
Check the oil pump using EngineEARs and probe at the oil filter
Yes
adapter to verify the oil pump as a source.
INSTALL a new oil pump. REFER to Section
303-01a for 2.0L Zetec engine or Section
Is the oil pump the source of the noise?
303-01b for 3.0L (4V) engine. TEST the system
for normal operation.
No
Go to B7.
B7
CHECK VALVE LIFTERS OR LASH ADJUSTERS FOR
CORRECT OPERATION
Check valve lifter/lash adjuster for correct operation, using
Yes
EngineEARs.
VERIFY customer concern. CONDUCT a
diagnosis of other suspect components.
Are the valve lifters/lash adjusters operating correctly?
No
INSTALL a new valve lifter/lash adjuster(s).
TEST the system for normal operation.
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100-04-39
Noise, Vibration and Harshness
100-04-39
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST C : FRONT ENGINE ACCESSORY DRIVE BEARING HOOT
Test Step
Result / Action to Take
C1
CHECK THE ACCESSORY DRIVE IDLER AND
TENSIONER PULLEY BEARINGS
Carry out the Vehicle Cold Soak Procedure in this section.
Yes
INSTALL a new pulley/idler. REFER to Section
Key in START position.
303-05 . CARRY OUT the Vehicle Cold Soak
Procedure and TEST the system for normal
Place an EngineEAR probe directly on the pulley center post or bolt to
operation.
verify which bearing is making the noise.
Key in OFF position.
No
CONDUCT a diagnosis on other suspect
Is either bearing making the noise?
accessory drive components.
PINPOINT TEST D : POWER STEERING MOAN
Test Step
Result / Action to Take
D1
CHECK THE POWER STEERING SYSTEM
Carry out the Vehicle Cold Soak Procedure in this section.
Yes
Go to D2.
Key in START position.
No
Turn the steering wheel while the noise is occurring and listen for
CONDUCT a diagnosis on other suspect
changes in sound pitch or loudness.
accessory drive components.
Key in OFF position.
Does the sound pitch or loudness change while turning the
steering wheel?
D2
VERIFY THE SOURCE
Key in START position.
Yes
VERIFY that the supply tube to the pump is
Place an EngineEAR probe near the power steering pump/reservoir
unobstructed. CHECK the fluid condition and
while the noise is occurring. While an assistant turns the steering
level. DRAIN the fluid and REFILL. CARRY OUT
wheel, listen for changes in sound pitch or loudness.
the Vehicle Cold Soak Procedure and TEST the
system for normal operation. REFER to Section
Key in OFF position.
211-02 .
Does the sound pitch or loudness change while turning the
steering wheel?
No
Normal system operation.
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