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Old 05-20-2005, 11:02 AM   #1
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Yeah, I was confused on the issue too. Which is why I just posted a new thread asking for clarification.


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Old 05-20-2005, 11:19 AM   #2
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I responded to the other thread - the fact is, the actuator box making noise is evidence that it is NOT broken - what it's doing is trying to move the manifold runners, but they won't go, usually because the linkage is busted at the arm/clip on the manifold. If the arm/clip is not visibly broken, you have to determine if it's moving correctly under operating conditions. If it's not broke, not moving, and making noise, then the runners themselves may be jammed.

I suppose the actuator could be making noise but not functioning correctly, but that would be a new one on me. If after you have performed all the diagnostics I described you still think it's the box itself, take it in and make Ford do it. If you tear into the actuator box, you have probably voided the warranty on that part.

If I want something done under warranty, I usually try to do that diagnostics myself so I just have to point the dealer tech in the right direction.
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Old 05-20-2005, 03:22 PM   #3
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My waranty has long been up. Otherwise I would have brought it to them in the first place. When I unplugged the DSI actuator, which you can see has been done in the pics above, the noise stopped. SO I know it's coming from that box!!
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Old 05-20-2005, 03:45 PM   #4
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Yes, the noise is coming from that box, but it's highly unlikely that is what is broken - the noise coming from the box, if anything, means that the actuator is working. Otherwise you'd hear nothing. The noise is coming from the box because the actuator motor keeps trying to switch the intake runners and it can't because your cable end is almost certainly busted, or the place where the cable mounts on the intake is broken, and thus the cable is just flopping around loose.

Did you check the clip to see if it was actually attached to anything? It should be solidly attached.

If your problem is not the cable/clip assembly but is actually the motor/actuator assembly, I'd be surprised, and you'd probably be the first person to have that problem. I don't believe I've seen anyone say that part has failed on them...
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Old 05-20-2005, 04:02 PM   #5
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AAAHHHH. This makes much more sense!!!! When my car gets back from the shop with my new clutch and flywheel I will take a look!!! Thanx for clarifying that!!
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Old 05-20-2005, 04:26 PM   #6
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Since you apparently have the stock intake, it will be kind of hard to see the cable - if you can, take at least the top part off the intake (or just the whole airbox) because it gives you a much better view of the cable/clip and more room to get your hands in there and see if it's attached or broken off.
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Old 05-20-2005, 04:29 PM   #7
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Sounds good! maybe I'll install an AEM intake while I'm at it!
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