Damaged Tumble flaps make clacking noises?

whynotthinkwhynot · Mar 10, 2012

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.

Djzx3 · Mar 10, 2012

Its got to be able to wear out. I've seen plenty stuck open or closed.

whynotthinkwhynot · Mar 10, 2012

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.

felixthecat · Mar 10, 2012

Delete the IMRC you would need a tune

whynotthinkwhynot said:
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

whynotthinkwhynot · Mar 11, 2012

felixthecat said:
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.

drjkel · Mar 11, 2012

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.

whynotthinkwhynot · Mar 12, 2012

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.

sutyak · Mar 12, 2012

I think I have a spare 2.0 duratec manifold that I'll never use if you're interested.

badazz2010focus · Mar 12, 2012

i keep forgetting that these pesky fords have tumble flaps LOL!

felixthecat · Apr 10, 2012

What'd you end up doing?

whynotthinkwhynot said:
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?

AMMO-Duke · Apr 12, 2012

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.

fastfocus2005 · Apr 12, 2012

I had the same problem with my 2.3...a new manifold is $300 from the dealer!!

fastfocus2005 · Apr 12, 2012

the individual flaps and inserts at the ports of the manifold are not available separate...you have to buy the whole manifold!

felixthecat · Apr 12, 2012

Ammo-Duke is on to something

[clap]

fastfocus2005 said:
the individual flaps and inserts at the ports of the manifold are not available separate...you have to buy the whole manifold!

Ammo-Duke is saying to delete them altogether= imrc= aka tumble flaps. Read his above post. [clap]

matmatician · Jul 14, 2012

Not to turn this into a zombie thread, but in case someone in the future reads this, I JUST had this happen with my focus. The mechanic took the stethoscope to the head and listened for bad lifters, and they all sounded good. Yes, the tumble flaps make noise like bolts on a blender if they're bad. In my case, they would settle down after running for about 10 minutes and sound pretty normal until the car sat and I'd fire it up again. The fix was a new intake manifold.

felixthecat · Jul 14, 2012

matmatician said:
Not to turn this into a zombie thread, but in case someone in the future reads this, I JUST had this happen with my focus. The mechanic took the stethoscope to the head and listened for bad lifters, and they all sounded good. Yes, the tumble flaps make noise like bolts on a blender if they're bad. In my case, they would settle down after running for about 10 minutes and sound pretty normal until the car sat and I'd fire it up again. The fix was a new intake manifold.

So how many miles on your motor? I pulled the imrc actovator off & laided it a side & tie wrapped the flaps open, going on two months now w/ no issues. The fix is a escape manifold or pull the flaps & shaft out & JB weld the shaft holes.

matmatician · Jul 15, 2012

felixthecat said:
So how many miles on your motor? I pulled the imrc actovator off & laided it a side & tie wrapped the flaps open, going on two months now w/ no issues. The fix is a escape manifold or pull the flaps & shaft out & JB weld the shaft holes.

on the motor the IM was originally from, 73,000 miles.

Semir · Jul 17, 2012

I could probably pull one from the junkyard for you. There's a few 2.3 intake manifolds if you want one...pay shipping and the cost of the part it's yours

matmatician · Jul 17, 2012

I already got a new one installed :/ thanks for the offer though!

Semir · Jul 17, 2012

Hopefully you got it for cheap! There's a junkyard near me, pick n pull yourself an save a lot of money...TONS of foci

Damaged Tumble flaps make clacking noises?

whynotthinkwhynot

Djzx3

whynotthinkwhynot

felixthecat

whynotthinkwhynot

drjkel

whynotthinkwhynot

sutyak

badazz2010focus

felixthecat

AMMO-Duke

fastfocus2005

fastfocus2005

felixthecat

matmatician

felixthecat

matmatician

Semir

matmatician

Semir

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