2012 Titanium Front Strut Low Speed Noise (Clunk/Rattle)

[hand-filer]

I just came in from the garage. This rattle is pretty much driving me nuts! I removed the left front wheel and started tapping around with a dead blow hammer.
Everything feels and sounds solid.
Then I gave the inner fender a bit of a tap with my fist. Well that made a sound like the fender was going to fall off!!!
Not only is it loud, the fact that the inner fender is sort of kind of parabolically shaped amplifies the rattle considerably. I wonder if this might be my noise source?
It takes just the right road surface condition to cause it to happen, like bad expansion joints , 1" sudden drops where an approach meets the road etc.
I'm going to remove both inner fenders on the weekend and take a short drive to confirm if this is a problem. If it is, I'll find a way to isolate the points of contact. Might even consider applying sound deadener to the inner surface of the inner fender.
I'll report back at some point during the weekend and let you all know what I find.

[Zillon]

Originally Posted by dyn085

What does this leave us with? Struts? An out-of-tolerance fastener? Weak mounts?

Frustration. That's what it leaves us with.

I'm still waiting on my parts from Tousley... so, it's gonna be a while until we know if even those parts makes a difference.

[MAD916]

500 miles with my Ksport Coliovers and they are silent.... haven't bothered to look closer at the stock stuff that is in a box in my garage but will this weekend I'll be curious to see if there are any tell tale signs of blown struts or sloppy bearings???

[wilsonfocus86]

I noticed something suspicious lately. I know that the bulk of the clunk issue regards the SE sport package and Titanium Handling Packaged cars. I've been in and around a few dealerships here in Metro Detroit (because that's where I am back living). Oddly enough when browsing the all the Focus cars on dealers lots, I have not seen ONE Titanium with the handling package equipped (18" 5 spoke wheels which would be the tall tale sign); But I've seen numerous regular Ti's. Is it just me or are dealerships not ordering these cars because they don't want to deal with the TSB clunk issue, or are Ford only letting people who order them, get them? Just seems a bit, strange, to me. Food for thought.

[dyn085]

I've been thinking the same thing...

[suss6052]

Originally Posted by wilsonfocus86

I noticed something suspicious lately. I know that the bulk of the clunk issue regards the SE sport package and Titanium Handling Packaged cars. I've been in and around a few dealerships here in Metro Detroit (because that's where I am back living). Oddly enough when browsing the all the Focus cars on dealers lots, I have not seen ONE Titanium with the handling package equipped (18" 5 spoke wheels which would be the tall tale sign); But I've seen numerous regular Ti's. Is it just me or are dealerships not ordering these cars because they don't want to deal with the TSB clunk issue, or are Ford only letting people who order them, get them? Just seems a bit, strange, to me. Food for thought.

They already sold many SE Sport models as well as Ti w/handling package in Metro Detroit, one of my design leaders on the team I work with bought a Feburary build Ti w/ the handling package at the end of march before the $2000 incentive went away if you hadn't ordered one. I haven't heard them complaining about it although they did talk to me periodically about the DCT since they had also come from a 5mt in their 08 Focus.

[Wildsailor]

Originally Posted by wilsonfocus86

I noticed something suspicious lately. I know that the bulk of the clunk issue regards the SE sport package and Titanium Handling Packaged cars. I've been in and around a few dealerships here in Metro Detroit (because that's where I am back living). Oddly enough when browsing the all the Focus cars on dealers lots, I have not seen ONE Titanium with the handling package equipped (18" 5 spoke wheels which would be the tall tale sign); But I've seen numerous regular Ti's. Is it just me or are dealerships not ordering these cars because they don't want to deal with the TSB clunk issue, or are Ford only letting people who order them, get them? Just seems a bit, strange, to me. Food for thought.

The Ti's with the Handling Package are out there. I looked at a Sedan and a 5-door yesterday at a local Metro Detroit dealer. One dealer actually has (or had about 3 weeks ago, not sure now) quite a few manual versions. The more likely issue with this package not being more prevalent is the "Summer Tires." If a customer reads that and they live in a northern market they will pass. As a result, the dealers are hesitant to order too many of them for fear of them not selling.

[Zillon]

I think it has more to do with dealers simply not ordering fully-optioned cars, since the more expensive cars are tougher to sell.

However, looking at my google document spreadsheet of people's suspension issues, a lot of the cars are, in fact, SE Sports or Ti w/the handling package.

Spreadsheet: https://docs.google.com/spreadsheet/...ENDlUekE#gid=0

If anyone still wishes to add to the spreadsheet, please click and fill out this form: https://docs.google.com/spreadsheet/...lUekE6MQ#gid=0

Here's a question: Do the non-Sport SEs, SELs, and Tis have this mass damper on the struts? (Black arrow)


According to Edmunds (in this article: CLICK), it's been installed by Ford to "quell an unwanted resonant vibration" in the suspension.

[TiPilot]

My car's a non-handling package Ti and I have the rattle...

[FordCustomerService]

Originally Posted by Sonic_HedgeHog

Thomas... Where are my parts? I haven't heard anything from my dealer since they said they ordered the parts, it's been like three weeks...

I'll have your Customer Service Manager look into it; please shoot me a PM with your VIN, mileage, phone number, and dealer name.

Originally Posted by Zillon

I'm still waiting on my parts from Tousley... so, it's gonna be a while until we know if even those parts makes a difference.

Are these Ford or aftermarket parts? I only ask because Tousley is the name of one of our dealers.

Originally Posted by DarinS

Mine is going back in tomorrow to get looked at again. During my original appointment they replaced the passenger side strut mount and shock, but the noise came back within a week and has steadily been getting worse. Hopefully things go better this time.

Please keep me updated! If you'd like for me to loop in your area's Customer Service Manager, please PM me your VIN, mileage, phone number, and dealer info. If you need other routine maintenance performed, remember these to save your hard-earned dough: http://owner.ford.com/servlet/Conten...iceCouponsPage.

Originally Posted by dyn085

...Ford, as a business, has done (imho) a decent job of trying to rectify the situation...

...Sonic, I actually got a call that my bearings are in. I may try to pick them up this week and see if I have enough time to install them this weekend. Here's to praying it works

Thank you kindly! I have my fingers crossed for you, good sir. Remember, this is a good job for your dealer.

Originally Posted by hand-filer

For those of you that are pinning your hopes on TSB 12-6-17 fixing your rattle/clunk issue, don't get your hopes up too high like I did. 1,200 miles after having it applied to both sides, the noise is back as bad as ever. This is ridiculous and the 88 pages of this thread speaks volumes...

Please contact our Canadian Customer Relationship Centre for further assistance at 800-565-3673.

Originally Posted by wilsonfocus86

I could notice hints of the "clunk" after going over some pretty good curbs. About 20 miles into getting my car back.

I'm hoping this most recent service will do the trick. So you've only had it back for 20 miles now?

Originally Posted by wilsonfocus86

I noticed something suspicious lately. I know that the bulk of the clunk issue regards the SE sport package and Titanium Handling Packaged cars. I've been in and around a few dealerships here in Metro Detroit (because that's where I am back living). Oddly enough when browsing the all the Focus cars on dealers lots, I have not seen ONE Titanium with the handling package equipped (18" 5 spoke wheels which would be the tall tale sign); But I've seen numerous regular Ti's. Is it just me or are dealerships not ordering these cars because they don't want to deal with the TSB clunk issue, or are Ford only letting people who order them, get them?...

Originally Posted by dyn085

I've been thinking the same thing...

Originally Posted by suss6052

They already sold many SE Sport models as well as Ti w/handling package in Metro Detroit, one of my design leaders on the team I work with bought a Feburary build Ti w/ the handling package at the end of march before the $2000 incentive went away if you hadn't ordered one. I haven't heard them complaining about it although they did talk to me periodically about the DCT since they had also come from a 5mt in their 08 Focus.

Originally Posted by Wildsailor

The Ti's with the Handling Package are out there. I looked at a Sedan and a 5-door yesterday at a local Metro Detroit dealer. One dealer actually has (or had about 3 weeks ago, not sure now) quite a few manual versions. The more likely issue with this package not being more prevalent is the "Summer Tires." If a customer reads that and they live in a northern market they will pass. As a result, the dealers are hesitant to order too many of them for fear of them not selling.

Originally Posted by Zillon

I think it has more to do with dealers simply not ordering fully-optioned cars, since the more expensive cars are tougher to sell.

However, looking at my google document spreadsheet of people's suspension issues, a lot of the cars are, in fact, SE Sports or Ti w/the handling package...

Hey everyone -

It's basically supply and demand. We won't assemble models with known issues. These trim levels are out there. I'll be happy to conduct a little search on my end; be sure to check your areas too: http://www.showroom.ford.com/FDShowr...ntory&zipcode=.

Type to you soon,

Thomas