Suspension Clunking TSB 97-2-5

97-2-5, Publication Date: JANUARY 20, 1997

FORD:

1996-97 TAURUS SHO, TAURUS

LINCOLN-MERCURY:

1995-97 CONTINENTAL

1996-97 SABLE

ISSUE:

There may be a "clunking" noise from the front suspension of the vehicle. This may be due to early wear of the sway bar links.

ACTION:

Install a revised design sway bar link. The new links have an improved lip seal to keep out contaminants and reduce the possibility of early wear-out. Refer to the following Service Procedure for details.

SERVICE PROCEDURE

1. Road test the vehicle to verify the concern. Noise from a loose sway bar link is typically referred to as "clunking, popping, knocking, or rattling." This noise is noticed when encountering small bumps in the road at low speed as opposed to noises that occur when turning or on acceleration/deceleration. Use of Rotunda Chassis Ears (107-R2102) is highly recommended to ensure accurate diagnosis.

NOTE:

SWAY BAR LINKS ARE EASILY IDENTIFIABLE FOR HAVING END PLAY OR LOOSENESS WHILE ON THE VEHICLE. IT IS NOT NECESSARY, OR ADVISABLE, TO REMOVE THEM FROM THE VEHICLE FOR DIAGNOSIS.

2. If the sway bar links are suspect, raise the vehicle on a hoist as outlined on Page 00-02-1 of the appropriate year Continental or Taurus/Sable Service Manual.

3. Hold the sway bar link firmly in one hand against the shock strut joint, the sway bar lever arm firmly in your other hand, and shake the sway bar lever arm vertically. To check if the top joint has play, hold the link firmly against the sway bar and shake the sway bar link and lever arm vertically. This also helps in determining if the sway bar link joint is loose, or the attaching fastener is loose. If any movement is evident in the link joint, install new sway bar links as outlined in the appropriate year Continental or Taurus/Sable Service Manual, Page 04-01-13. Retorque any loose fasteners to the required torque specifications.

NOTE:

THE SWAY BAR LINK ATTACHING NUTS SHOULD BE DISCARDED AND REPLACED WHENEVER A LINK IS SERVICED.