Sub Frame Clunk TSB 97-2-3

97-2-3, Publication Date: JANUARY 20, 1997

FORD:

1996-97 TAURUS

LINCOLN-MERCURY:

1995-97 CONTINENTAL

1996-97 SABLE

ISSUE:

A "clunk" noise on heavy acceleration and/or deceleration or on turns may be heard and/or felt in the floor pan area. This may be caused by the rear lower subframe insulators allowing movement between the mounts and the subframe.

ACTION:

Replace the rear lower subframe insulators. The revised Insulators (F7DZ-5400155-AA) are designed with a conical center to minimize movement between the subframe and the insulator. Refer to the following Service Procedure for details.

SERVICE PROCEDURE

NOTE:

BEFORE RAISING VEHICLE, TURN OFF AIR SUSPENSION IF EQUIPPED.

1. Support the rear of the subframe. Loosen the left rear subframe bolt. Remove the existing left lower subframe insulator and replace it with a revised left lower subframe insulator.

2. Loosen the right rear subframe bolt. Remove the existing right lower subframe insulator and replace it with a revised right lower subframe insulator.

3. Maintain support during the torquing of the subframe-to-body bolts to 80 ±12 N-m (59 ±9 lb-ft) for Continental and 90 ±14 N-m (66 ±10 lb-ft) for Taurus and Sable.

CAUTION:

DO NOT TORQUE THE SUBFRAME BOLTS WITHOUT SUPPORTING THE REAR OF THE REAR SUBFRAME. BE SURE TO USE THREADLOCK AND SEALER (EOAZ-19554-AA OR EQUIVALENT MEETING FORD SPECIFICATION WSK-M2G351-A5) ON ALL REAR SUBFRAME BOLTS BEFORE REINSTALLING AND TORQUING. THE SUBFRAME MUST BE SUPPORTED DURING SERVICE USING ROTUNDA HI-LIFT JACK (014-00950) AND ROTUNDA SUBFRAME REMOVAL KIT (014-00751).