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

jrn146 · Aug 27, 2012

Ford doesn't seem the least bit interested in fixing this problem. How many people need to complaint before something is done? This isn't rocket science. The old models didn't clunk. Can't they go back to that style bearing/strut assembly?

Timthom62 · Aug 27, 2012

jrn146 said:
Ford doesn't seem the least bit interested in fixing this problem...

I don't know that I'd say that. They've issued Two TSBs (that I'm aware of), changed the design of some of the parts involved (or so I'm told), and changed a lot of parts on a lot of cars. The process is still ongoing.

We have a clunk/rattle from both front struts on our SE, and had held out hope for the latest TSB to be the final fix. They're not quite there yet, but as the service manager at our dealer told me Friday, they're still working toward a final fix.

You might argue that the money could have been better spent on the design in the first place, but hindsight is 20/20. You could argue that they should have resolved it by now, because as you noted it isn't rocket science. It is, however, a bit unfair to say that they're not interested.

jrn146 · Aug 27, 2012

Tim, I get what you're saying but the TSB's aren't addressing the clunk. They're for grinding/moaning noise but they happened to fix some peoples clunks, at least temporarily. They are still saying the clunk is a "normal" noise and until Ford says otherwise the dealers, at least mine, won't do any more. That sounds to me like they aren't acknowledging the clunk as a problem at this time.

FordService · Aug 27, 2012

dogma_not said:
I am one of those posters here. Ford lubed the strut jounce bumpers on July 25 and so far the noise hasn't returned. I was skeptical that lube was a fix, but I suggest some others try it and see what happens. Nothing to lose.

jcbbas said:
So had my car in for service yesterday for this problem. They replaced basically everything on both sides. As of right now the sound is completely gone. On my invoice it said something about a TSB. I dont have the paper on me right now so I dont know the TSB number or date. Will post later when I get off work. Just glad to not hear the sound that my 14 year old car had...

me.awesome said:
So just got mine back from getting the cluck fixed along with a bunch of other things. First i gotta say the dealership i went too was absolutely FANTASTIC. Even though some of my problems, vibrations, weren't fixed fully, they are defiantly better, plus they said to bring it back if there are more and were super supportive of me bringing it back. Anywho, they looked at the struts using the TSB and come to find out that one of my strut bearings WAS BROKEN IN HALF. They said this was the first time they've seen that happen. But i am so glad i brought it in now.
They also fixed a bunch of other TSBs and the car is so much better. Got the highway drift, and the clutch imbalance issues figured out. So glad i took it to my current dealer, just awesome!

You three are clunk-free! [headbang] If any of you would like to submit positive feedback, please PM me your VIN, mileage, phone number, and name of dealer; I'll make sure the Customer Service Managers recognize that your service departments went above and beyond the call of duty.

TiPilot said:
Apparently it really did change things. She called today and said the parts will be at the dealer tomorrow or Monday.

Sonic_HedgeHog said:
Mine has always and only been the passenger side

ChrisRyan said:
I have a 7am appointment tomorrow at the dealer. The first dealer I called was useless and didn't want to look at the car. So the next one I called was very quick about making an appointment. Anyways I hope I can get some resolution soon.

revhigh said:
My parts are finally in (took about a month), and my car goes in Tuesday for the fix. My dealer has been fantastic. I went in WITHOUT an appointment to have them hear the noise. I drove around the building with the service manager to demonstrate it (it took all of about 20 feet, and he heard it) finished driving around the building, and he wrote me up and ordered the parts.

Lipshurt said:
Well after two weeks, my clunks and rattle are pretty much raging in full force. At least when the temp gets to about 68 degrees. This morning it was 63 degrees, and it was falling apart.

I emailed Paul worrall, service manager at heller ford in escondido a couple of times. No reply yet. He was very confident and said this problem is "not rocket science" etc.

I also talked to "Brian" my regional service rep and tried to get the name of someone above him to talk to. He said that he is the highest level person that is allowed to talk with customers...

killjoy said:
I guess add another for the noise...They had the part in stock quick but they are waiting for a separate part (c-channel for front passenger seat) to come off back-order 8/25.

knightp25 said:
...the 2012 model is JUNK. mine also makes the clunking sound, and i hate like he** to get a brand new car taken apart to get fixed already. This is only one of a couple of problems i am experiencing...

Keep us all updated on the end results. If you'd like, please PM me your VIN, mileage, phone number, and dealer name; I'll have your regional Customer Service Managers grab each bull by the horns. [strongman]

jrn146 said:
Ford doesn't seem the least bit interested in fixing this problem. How many people need to complaint before something is done? This isn't rocket science. The old models didn't clunk. Can't they go back to that style bearing/strut assembly?

Timthom62 said:
I don't know that I'd say that. They've issued Two TSBs (that I'm aware of), changed the design of some of the parts involved (or so I'm told), and changed a lot of parts on a lot of cars. The process is still ongoing.

We have a clunk/rattle from both front struts on our SE, and had held out hope for the latest TSB to be the final fix. They're not quite there yet, but as the service manager at our dealer told me Friday, they're still working toward a final fix...

Our Customer Relationship Center and tech hotlines are proactively documenting all feedback concerning this suspension clunk; all of us are doing our parts and then some. [thumb] Since it's a completely different build, the old style may not suffice. Are you guys currently working with your Customer Service Managers? If not, please PM me your VIN, mileage, phone number, and dealer name; I'll get them involved.

Thomas

Sonic_HedgeHog · Aug 27, 2012

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...

DarinS · Aug 27, 2012

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.

dyn085 · Aug 27, 2012

jrn146 said:
Tim, I get what you're saying but the TSB's aren't addressing the clunk. They're for grinding/moaning noise but they happened to fix some peoples clunks, at least temporarily. They are still saying the clunk is a "normal" noise and until Ford says otherwise the dealers, at least mine, won't do any more. That sounds to me like they aren't acknowledging the clunk as a problem at this time.

I don't know, it sounds more like you have a dealership issue than Ford not acknowledging the problem. Ford, as a business, has done (imho) a decent job of trying to rectify the situation. It may not be fully resolved, but they issued a TSB update less than 30 days ago. That sounds like they are still trying.

Have you tried another dealership?

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[cheers]

hand-filer · Aug 27, 2012

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.
Ford corporate if you're lurking around on this forum (not likely); you have lost yourselves another repeat customer.

wilsonfocus86 · Aug 27, 2012

hand-filer said:
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.
Ford corporate if you're lurking around on this forum (not likely); you have lost yourselves another repeat customer.

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

dyn085 · Aug 28, 2012

hand-filer said:
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.
Ford corporate if you're lurking around on this forum (not likely); you have lost yourselves another repeat customer.

wilsonfocus86 said:
I could notice hints of the "clunk" after going over some pretty good curbs. About 20 miles into getting my car back.

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

Frustration. That's what it leaves us with.

hand-filer · Aug 28, 2012

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 · Aug 28, 2012

dyn085 said:
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 · Aug 28, 2012

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 · Aug 28, 2012

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 · Aug 28, 2012

I've been thinking the same thing...

suss6052 · Aug 28, 2012

wilsonfocus86 said:
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 · Aug 28, 2012

wilsonfocus86 said:
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 · Aug 28, 2012

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/ccc?key=0AryS5DT8rzV-dHRWZGY2b3pVTEVpT3dTWUpENDlUekE#gid=0

If anyone still wishes to add to the spreadsheet, please click and fill out this form: https://docs.google.com/spreadsheet/viewform?pli=1&formkey=dHRWZGY2b3pVTEVpT3dTWUpENDlUekE6MQ#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 · Aug 28, 2012

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

FordService · Aug 28, 2012

Sonic_HedgeHog said:
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. [thumb]

Zillon said:
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. [

]

DarinS said:
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/ContentServer?pagename=Owner/Page/ServiceCouponsPage.

dyn085 said:
...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[cheers]

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

hand-filer said:
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.

wilsonfocus86 said:
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. [giddy] So you've only had it back for 20 miles now?

wilsonfocus86 said:
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?...

dyn085 said:
I've been thinking the same thing...

suss6052 said:
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 said:
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 said:
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/FDShowroom.jsp?branding=1&lang=en&makeTransition=inventory&zipcode=. [thumb]

Type to you soon, [ffrocks]

Thomas

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

jrn146

Timthom62

jrn146

FordService

Sonic_HedgeHog

DarinS

dyn085

hand-filer

wilsonfocus86

dyn085

hand-filer

Zillon

MAD916

wilsonfocus86

dyn085

suss6052

Wildsailor

Zillon

TiPilot

FordService

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