2012 Titanium Front Strut Low Speed Noise (Clunk/Rattle) - Page 173 - Ford Focus Forum, Ford Focus ST Forum
Ford Focus Forum
HomeContact UsAbout UsGalleryDiscussion ForumsMarketplace


Go Back   Ford Focus Forum, Ford Focus ST Forum > Ford Focus Third Generation > MK3 TSB, Recall & Problems Archive

MK3 TSB, Recall & Problems Archive The place to chat about TSB and Known Issues for the 2012 Focus.

Search This Forum | Image Search | Advanced Search    
Ford Focus Tire & Wheels FocusFanatics Merchandise

Reply
 
Thread Tools Display Modes
Old 01-02-2013, 09:01 AM   #1721
Dysan911
Focus Addict
 
Join Date: Feb 2012
Fan#: 95746
Location: Jacksonville, FL
What I Drive: 2012 White, Focus Titanium

Posts: 582
FF Reputation: 2 Dysan911 Good Standing Member
Buy-Sell-Trade Rating: (0)
Quote:
Originally Posted by Zillon View Post
If you're looking to blame the alloy LCAs on the handling pack, don't. The '13 SE gets them standard now.

From all my digging, fixing, and tweaking, I'm pretty certain that the welds joining the strut tower to the firewall sheetmetal are the source of the issue. It's likely a problem they fixed in production, but won't apply a fix for early production cars due to difficulty in maintaining standards for the fix and the labor involved.

If I'm right, it's not something that can be fixed with a simple parts swap; it will require additional spot welding or the injection of some sort of caulk or epoxy.

Z, The only issue I have with your hypothesis regarding the welds is. Why did the replacement of parts fix my issue for 6mos. I know they didn't inject any type of caulk or epoxy. I suspect from my paperwork they only replaced the one side and now the noise is back on the side they didn't fix. If it were truly the welds.. After the replaced the front end parts the noise would have still been present IMHO.
__________________
2012 FF Ti HB Platinum White Tricoat, Built 12/11, 401A + Parking Technology Package and MFT w/NAV at 3.5.1
Dysan911 is offline  
    Reply With Quote
Sponsored Links
Advertisement
 
Old 01-02-2013, 10:52 AM   #1722
Zillon
Focus Addict
 
Zillon's Avatar
 
Join Date: Jan 2005
Fan#: 17393
Location: Philthadelphia, PA
What I Drive: '13 GTI

Posts: 1,387
FF Reputation: 27 Zillon Great Standing Member
Buy-Sell-Trade Rating: (3)
Quote:
Originally Posted by Dysan911 View Post
Z, The only issue I have with your hypothesis regarding the welds is. Why did the replacement of parts fix my issue for 6mos. I know they didn't inject any type of caulk or epoxy. I suspect from my paperwork they only replaced the one side and now the noise is back on the side they didn't fix. If it were truly the welds.. After the replaced the front end parts the noise would have still been present IMHO.
Valid points. However, I too observed the same thing; every time I replaced my parts, the noise temporarily went away too.

I also noticed that when I tightened the strut mount bolts, the noise was reduced or went away.

I feel that following the install of fresh strut mounts, it takes some time for the rubber to seat in and loosen up, and that all depends on temperatures, how much, and how hard the car is driven. Mine came back after a month, following the install of new strut mounts, strut bearings, and bolts.

Something else to note, is that every time I replaced parts or tightened bolts, the noise always came back on the same exact side in the same exact manner, which points to an issue with the structure, or at least something outside of the strut/spring/mount/bearing.
__________________
Joined the dark side.
Zillon is offline  
    Reply With Quote
Old 01-03-2013, 08:55 AM   #1723
FordService
Official Ford Rep
 
FordService's Avatar
 
Join Date: Oct 2010
Fan#: 79824
Location: Dearborn, MI
What I Drive: Ford Focus

Posts: 4,291
Points 3,106, Level 34
Points: 3,106, Level: 34 Points: 3,106, Level: 34 Points: 3,106, Level: 34
Level Up 38% Completed
Level up: 38% Level up: 38% Level up: 38%
Forum Activity 23%
Activity: 23% Activity: 23% Activity: 23%
FF Reputation: 18 FordService Great Standing Member
Buy-Sell-Trade Rating: (0)
Quote:
Originally Posted by Dysan911 View Post
...I suspect from my paperwork they only replaced the one side and now the noise is back on the side they didn't fix...
Dysan911,

In case you missed my earlier post, I want to send this up the line to the customer service manager for your area. Please drop me a line via PM with your contact info (including your phone number, full name, VIN, mileage, and dealer details).

Cory
__________________
FORD SERVICE

p: 800.392.FORD
t: @FordService @FordFocus @Ford
f: facebook.com/FordServiceUS facebook.com/FordFocus

M - F 11 a.m. - 8 p.m. ET | Send a PM? Pls allow 2 business days for reply
FordService is offline  
    Reply With Quote
Old 01-03-2013, 01:11 PM   #1724
Dysan911
Focus Addict
 
Join Date: Feb 2012
Fan#: 95746
Location: Jacksonville, FL
What I Drive: 2012 White, Focus Titanium

Posts: 582
FF Reputation: 2 Dysan911 Good Standing Member
Buy-Sell-Trade Rating: (0)
Hey Z,

Did you ever replace the bearings? Motorcraft AD1094. I'm pretty sure the noise is coming from this because its directly bolted to the sheetmetal (Strut Tower) thats connected to the firewall of the car which really amplifies the sound.

People have asked on here what the clunk sounds like. Imagine if you loosened those strut tower bolts and went over some bumpy roads. I bet it would sound the same. Which is why the first thing we try is to tighten those up.

Has anyone been able to tighten the center bolt? Most of the strut towers I see in other cars you can see the large nut in the center. On the focus it's covered by that plate. If the plate were removed and someone attempted to tighten the center bolt would that make any difference?
__________________
2012 FF Ti HB Platinum White Tricoat, Built 12/11, 401A + Parking Technology Package and MFT w/NAV at 3.5.1
Dysan911 is offline  
    Reply With Quote
Old 01-03-2013, 01:26 PM   #1725
suss6052
Focus Addict
 
suss6052's Avatar
 
Join Date: Feb 2012
Fan#: 95752
Location: ..., MI
What I Drive: 2013 Ford Focus ST2 Ingot Silver

Posts: 12,448
Points 9,448, Level 65
Points: 9,448, Level: 65 Points: 9,448, Level: 65 Points: 9,448, Level: 65
Level Up 33% Completed
Level up: 33% Level up: 33% Level up: 33%
Forum Activity 29%
Activity: 29% Activity: 29% Activity: 29%
FF Reputation: 23 suss6052 Great Standing Member
Buy-Sell-Trade Rating: (3)
Quote:
Originally Posted by Dysan911 View Post
Hey Z,

Did you ever replace the bearings? Motorcraft AD1094. I'm pretty sure the noise is coming from this because its directly bolted to the sheetmetal (Strut Tower) thats connected to the firewall of the car which really amplifies the sound.

People have asked on here what the clunk sounds like. Imagine if you loosened those strut tower bolts and went over some bumpy roads. I bet it would sound the same. Which is why the first thing we try is to tighten those up.

Has anyone been able to tighten the center bolt? Most of the strut towers I see in other cars you can see the large nut in the center. On the focus it's covered by that plate. If the plate were removed and someone attempted to tighten the center bolt would that make any difference?
From what I've read he replaced the bearings multiple times with little to no change in effect, it may have gotten quiter for a while with new parts, but eventually the clunk kept coming back to the point where he couldn't stand to deal with it any more.
__________________
Moderator for: DURATEC Ti-VCT Performance, ST Performance, MK3 Focus
suss6052 is online now  
    Reply With Quote
Old 01-03-2013, 01:48 PM   #1726
Zillon
Focus Addict
 
Zillon's Avatar
 
Join Date: Jan 2005
Fan#: 17393
Location: Philthadelphia, PA
What I Drive: '13 GTI

Posts: 1,387
FF Reputation: 27 Zillon Great Standing Member
Buy-Sell-Trade Rating: (3)
Quote:
Originally Posted by Dysan911 View Post
Hey Z,

Did you ever replace the bearings? Motorcraft AD1094. I'm pretty sure the noise is coming from this because its directly bolted to the sheetmetal (Strut Tower) thats connected to the firewall of the car which really amplifies the sound.

People have asked on here what the clunk sounds like. Imagine if you loosened those strut tower bolts and went over some bumpy roads. I bet it would sound the same. Which is why the first thing we try is to tighten those up.

Has anyone been able to tighten the center bolt? Most of the strut towers I see in other cars you can see the large nut in the center. On the focus it's covered by that plate. If the plate were removed and someone attempted to tighten the center bolt would that make any difference?
Replaced the strut bearings and mounts twice. Each time, the noise improved, then got worse.

I also over-torqued the strut mount bolts, replaced the bolts, used different bolts, all to the same effect. I'd tighten everything up, and the noise would come back.

I tried tightening the center strut nut, however, overtightening this will lead to creaking. I don't recommend going past the factory spec of 50 ft-lbs.

I also checked the torque on the subframe bolts, insulated the cowl with rubber weatherstripping, and tried all sorts of remedies.

I even went so far as to find that the Focus ST and 2013 Foci were shipping with an entirely different strut tower brace made out of a heavier material. I bought the brace, installed it, and noted a minimal improvement.

The one thing I didn't do was try to fill the airgap between the sheetmetal pinch welded to the strut tower and the strut tower itself with some sort of epoxy or caulk. This area did rattle when struck with a rubber screwdriver handle.

By the time I discovered the pinch welded area that rattled, I had returned the car to 100% stock in preparation to send the car to the dealer one last time. At that point, however, I weighed my options. After putting that much time and effort into what was effectively an exercise in chasing my own tail, I threw in the towel and traded the car in.
__________________
Joined the dark side.
Zillon is offline  
    Reply With Quote
Old 01-03-2013, 02:00 PM   #1727
Dysan911
Focus Addict
 
Join Date: Feb 2012
Fan#: 95746
Location: Jacksonville, FL
What I Drive: 2012 White, Focus Titanium

Posts: 582
FF Reputation: 2 Dysan911 Good Standing Member
Buy-Sell-Trade Rating: (0)
Quote:
Originally Posted by Zillon View Post
Replaced the strut bearings and mounts twice. Each time, the noise improved, then got worse.

I also over-torqued the strut mount bolts, replaced the bolts, used different bolts, all to the same effect. I'd tighten everything up, and the noise would come back.

I tried tightening the center strut nut, however, overtightening this will lead to creaking. I don't recommend going past the factory spec of 50 ft-lbs.

I also checked the torque on the subframe bolts, insulated the cowl with rubber weatherstripping, and tried all sorts of remedies.

I even went so far as to find that the Focus ST and 2013 Foci were shipping with an entirely different strut tower brace made out of a heavier material. I bought the brace, installed it, and noted a minimal improvement.

The one thing I didn't do was try to fill the airgap between the sheetmetal pinch welded to the strut tower and the strut tower itself with some sort of epoxy or caulk. This area did rattle when struck with a rubber screwdriver handle.

By the time I discovered the pinch welded area that rattled, I had returned the car to 100% stock in preparation to send the car to the dealer one last time. At that point, however, I weighed my options. After putting that much time and effort into what was effectively an exercise in chasing my own tail, I threw in the towel and traded the car in.
Where exactly is this pinch weld area? Is there something that moves that it would make it rattle in this area?
__________________
2012 FF Ti HB Platinum White Tricoat, Built 12/11, 401A + Parking Technology Package and MFT w/NAV at 3.5.1
Dysan911 is offline  
    Reply With Quote
Old 01-03-2013, 02:07 PM   #1728
suss6052
Focus Addict
 
suss6052's Avatar
 
Join Date: Feb 2012
Fan#: 95752
Location: ..., MI
What I Drive: 2013 Ford Focus ST2 Ingot Silver

Posts: 12,448
Points 9,448, Level 65
Points: 9,448, Level: 65 Points: 9,448, Level: 65 Points: 9,448, Level: 65
Level Up 33% Completed
Level up: 33% Level up: 33% Level up: 33%
Forum Activity 29%
Activity: 29% Activity: 29% Activity: 29%
FF Reputation: 23 suss6052 Great Standing Member
Buy-Sell-Trade Rating: (3)
Quote:
Originally Posted by Dysan911 View Post
Where exactly is this pinch weld area? Is there something that moves that it would make it rattle in this area?
It is the air gap between the strut tower and the body side and firewall. When the strut tower is hit in this area it seems to make a noise similar to the rattling heard normally when driving.
__________________
Moderator for: DURATEC Ti-VCT Performance, ST Performance, MK3 Focus
suss6052 is online now  
    Reply With Quote
Old 01-03-2013, 02:26 PM   #1729
Zillon
Focus Addict
 
Zillon's Avatar
 
Join Date: Jan 2005
Fan#: 17393
Location: Philthadelphia, PA
What I Drive: '13 GTI

Posts: 1,387
FF Reputation: 27 Zillon Great Standing Member
Buy-Sell-Trade Rating: (3)
Quote:
Originally Posted by Dysan911 View Post
Where exactly is this pinch weld area? Is there something that moves that it would make it rattle in this area?
Think of this as two metal surfaces slapping together. That's what this rattle/clunk is. If you open the hood and stick your head behind the engine and under the cowl, and look left, you should see what I'm talking about.

Again, can't guarantee that this is the issue with yours, but I believe that it is a strong possibility. If the welds are just the slightest bit inconsistent on the assembly line, this could explain why some people have no issues whatsoever, yet others can't get rid of the clunk, despite numerous parts replacements.

It only takes a few millimeters.

Here's a link to my post: http://www.focusfanatics.com/forum/s...postcount=1651
__________________
Joined the dark side.
Zillon is offline  
    Reply With Quote
Old 01-03-2013, 08:29 PM   #1730
Dysan911
Focus Addict
 
Join Date: Feb 2012
Fan#: 95746
Location: Jacksonville, FL
What I Drive: 2012 White, Focus Titanium

Posts: 582
FF Reputation: 2 Dysan911 Good Standing Member
Buy-Sell-Trade Rating: (0)
Quote:
Originally Posted by Zillon View Post
Think of this as two metal surfaces slapping together. That's what this rattle/clunk is. If you open the hood and stick your head behind the engine and under the cowl, and look left, you should see what I'm talking about.

Again, can't guarantee that this is the issue with yours, but I believe that it is a strong possibility. If the welds are just the slightest bit inconsistent on the assembly line, this could explain why some people have no issues whatsoever, yet others can't get rid of the clunk, despite numerous parts replacements.

It only takes a few millimeters.

Here's a link to my post: http://www.focusfanatics.com/forum/s...postcount=1651

Z,

I'll have to get my head up under that cowl and see if I can locate that specific spot. Its hard to grasp exactly where this is from the pics. Interesting that you were able to duplicate the exact noise by tapping on it. This whole mess is so very strange. Ya know sometimes I can duplicate that very same hollow clunk if I tap light light on the brake pedal. This is just before the brake pedal stiffens up from the pressure of the master cylinder. Just that tiny bit of excess slack in the pedal at the begining. I assumed the sound was similar to the clunk because both items are in contact with the firewall (Master Cylinder & Strut Tower).
__________________
2012 FF Ti HB Platinum White Tricoat, Built 12/11, 401A + Parking Technology Package and MFT w/NAV at 3.5.1
Dysan911 is offline  
    Reply With Quote
Reply

Bookmarks & Social Networks

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -5. The time now is 11:14 PM.


Copyright 2002-2014 FocusFanatics.com. All Rights Reserved : Terms of Use : Privacy Policy : Advertise Information

Focus Fanatics Ford Focus Forum offers many fun ways for you to engage with other Ford Focus Owners from across the world. Whether it be about the aftermarket performance modifications, technical how-to's, European tuned suspension or awesome fuel economy similar to the Acura TLX or Fiesta ST. You can find all Ford Focus and Focus ST related information here. Join our Ford Focus discussion forums and chat with local Focus enthusiasts in your area.