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Old 03-09-2012, 09:25 PM   #1
whynotthinkwhynot
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Damaged Tumble flaps make clacking noises?

I read that one FF had issues with them, but I'm not certain that it could do that. I looked BRower64's thread about removing the tumble flaps, and I can see where it might wear out where the shaft meets the flap and cause it to be loose.

Anyway, that's my issue. The car sounds like the freaking valves are about to pop out. However, a mechanic's stethoscope reveals no strange sounds from the valve cover. I do get lots of clacking from the intake manifold. It could be injectors, which are also making noise, but it's hard to tell.

Has anyone else had problems like this?
140k miles.


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Old 03-09-2012, 10:28 PM   #2
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Its got to be able to wear out. I've seen plenty stuck open or closed.
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Old 03-10-2012, 09:41 AM   #3
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Yeah, I'm searching for parts right now. It might be cheaper to just get a new manifold. I hate to delete them because that would reduce fuel economy. Then again, it would probably be right about where it is now- 28-29 since I'm sure those aren't working correctly.

Whatever it is, I have to arrange/purchase the parts so that I can perform the repair in as little time as possible. One of my problems is that there aren't any 05+ Focuses in junkyards around here. We have one yard that purchases everything Ford, and they only sell big parts like Engines/transmissions/body. No used intake manifold from there. I'll just have to keep an eye out in the BST forum.
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Old 03-10-2012, 04:05 PM   #4
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Delete the IMRC you would need a tune

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Yeah, I'm searching for parts right now. It might be cheaper to just get a new manifold. I hate to delete them because that would reduce fuel economy. Then again, it would probably be right about where it is now- 28-29 since I'm sure those aren't working correctly.

Whatever it is, I have to arrange/purchase the parts so that I can perform the repair in as little time as possible. One of my problems is that there aren't any 05+ Focuses in junkyards around here. We have one yard that purchases everything Ford, and they only sell big parts like Engines/transmissions/body. No used intake manifold from there. I'll just have to keep an eye out in the BST forum.
If you delete the IMRC you will need a tune. That would probably cheaper than a new manifold
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Old 03-11-2012, 08:08 AM   #5
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If you delete the IMRC you will need a tune. That would probably cheaper than a new manifold
And lose low end torque + fuel economy, so how much longer after that before it costs more to have gone the cheaper route?

I haven't checked dealers yet, but the parts might be available separately.
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Old 03-11-2012, 08:48 AM   #6
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Our friends across the pond have been dealing with this issue. Apparently it was worse on pre-2003 duratecs:

http://www.robertjenkins.co.uk/mondeo/index.php

Whether or not the later 'tecs are immune is unknown. A decided clicking noise from the manifold is the tell-tale.
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Old 03-12-2012, 05:53 AM   #7
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OH crap. Manifold replacement/TF removal soon........ Fuuuuuuuuuuuuuuuuuu

I was hoping I'd have enough time to find another route besides replacement. Sheesh. Time to call Tousley Ford I suppose.
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Old 04-10-2012, 09:40 AM   #8
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What'd you end up doing?

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OH crap. Manifold replacement/TF removal soon........ Fuuuuuuuuuuuuuuuuuu

I was hoping I'd have enough time to find another route besides replacement. Sheesh. Time to call Tousley Ford I suppose.
So Alex, what did you end up doing?
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Old 04-11-2012, 08:12 PM   #9
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whynotthinkwhynot,

Here is something you can try. Disconnect the tumble flap actuator arm from the tumble flap control rod. Wire the control rod with the flaps in the open position. Leave the actuator hooked up and functioning, this way the ecu will not throw a code. This way, you can see how it runs without the flaps. I know some people believe they lost low-end, but that is not my experience. It has been my experience that you gain response and low-end.

If this works, you can just remove the flaps and be done with it. Also, there is no tuning I know of for tumble flap removal alone. If you leave the actuator in place and functioning, your ecu will not know the difference.

If you have the 2.0 and want to remove/disable the entire system, there is a lot of tuning involved. That is another subject.
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Old 04-11-2012, 09:36 PM   #10
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I had the same problem with my 2.3...a new manifold is $300 from the dealer!!
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