Body/Frame - Front End Growl/Flutter At Highway Speeds
TSB 11-4-604/27/11
NOISE FROM FRONT BOLSTER AT HIGHWAY
SPEEDS - BUILT ON OR BEFORE 2/4/2011
FORD:
2011 Explorer
ISSUE
Some 2011 Explorer vehicles built on or before 2/4/2011 may experience a flutter/growl/moan type noise from the front of the vehicle at highway speeds. The noise may be present at lower speeds depending on wind speed and direction. There may also be a slight vibration felt in the floor pan or related sheet metal during the noise concern. This may be due to the movement of a styrofoam insert located on the bolster just below the a/c condenser.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Detach lower fascia grille from fascia by pushing the grille toward the rear of the vehicle at each fastener location. Using a soft plastic wedge tool between the grille and the fascia will aid in the detachment of the grille. See Figure 1 for clip locations.
2. Once grille is detached, position it out of the way inside the fascia above the opening to gain access to the bolster area.
3. Verify that the styrofoam block below the condenser is clean and dry. Clean and dry it if dirty or wet. Sticky foam tape will need to be able to stick to the styrofoam block.
4. Remove the protective backing from the tape and apply the tape so half of it is directly under the edge of the condenser when stuck in place to the styrofoam block. It may be helpful to lay the foam tape on an angle to the condenser and roll the foam under the condenser edge. When installed properly, it should look like the cross section illustration. (Figure 2)
a. A/C Condenser
b. Foam Tape
c. Styrofoam Block Insert
d. Bolster
5. Reinstall fascia grille by gently pulling the grille towards the front of the vehicle at each clip location until the retainers lock into place.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
110406A 2011 Explorer: Install 0.3 Hr.
Foam Tape To secure
Foam Block (Do Not Use
With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
8349 42
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