2007 Front Suspension Thunking Noise - Page 61

wolfey2k · 03-29-2007, 01:30 PM

Quote:

ORIGINAL: FlyingTuna

Talked with the Svc Manager last night. He is going to order the brace that's on the convertibles and put it on Old Blue. I'll let you know how it works.

Cool. You may want to suggest that they install it with the suspension loaded. I don't know if this will make any difference but it might. Jay is still trying to fix the problem himself with no success.
Caper made and installed his own cross member recently with the suspension loaded and it stopped the thunking noise,,so far.

Is your dealer going to pay for the part and repair or are you?
Keep us posted on how it goes.

And I would suggest you have your dealer install new strut assemblies including strut mounts at the same time. Just in case your current mounts are shot. That can be done under warranty. Mine were.

Wolfey2k

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sandy · 03-29-2007, 03:31 PM

I solved my noise problem with eibach pro-kits and tokico struts (who knows why). I wonder if anyone else out there has this setup and still has a thunking noise?

Jays Mustang · 03-29-2007, 03:42 PM

I just got done with the front swaybar braces and they seemed to help a little too. Ties in the frontK-member with the rad. support frame at the top swaybar bolt. As I say, I live on a crappy road so it doesn't take long to know if things help. If I just could get on the main road firstI would swear the noise stopped but I have about 2 miles of crap to the main road or toget home. The G-Trac brace should be in tomorrow and see if I can mount that too. I'll tell you though, there's nothing weak to the bar I made. Same 1.25" thick as Caspers. If there is anything weak it's the mount that it's bolted to. Which is the same holes as the Ford one mounts to. So there's nothing different than Fords only ours is way stronger. It should be interesting when Flying installs his. He has the noise and would be the firstto have the Ford brace installed alone. It would be a waste of time to install new strut bearings if there the same crap as on ours. Going back to what I said ages ago, Ford put on crappy upper bearing out of the box on my car. If it had the brace would it have made a difference? I doubt it. I'm sure not every upper mount sucked or there would be a lot more people moaning on this thread. Well, time to look for a good strut tower brace then I'll have it as strong as I can make it. Then wait for the new upper bearing mount to come out.

Jays Mustang · 03-29-2007, 03:44 PM

Sandy did your kit come with new upper bearing mounts?

northy_polk · 03-29-2007, 03:53 PM

Quote:

ORIGINAL: sandy

I solved my noise problem with eibach pro-kits and tokico struts (who knows why). I wonder if anyone else out there has this setup and still has a thunking noise?

looks like GenMex2 had success with that, altho he added the HD strut mounts as well. And if my notes are correct, Vert7jax had luck with steeda springs, d-specs and endlinks [new ones???]. yes, who knows why is the refrain here.

Jays Mustang · 03-29-2007, 04:38 PM

Just a comment on front end load/unload. That was when you were mounting control arms with new bushings was when you wanted the chassic on it's wheels and on the ground. Then you'd tighten the bolts. If we have that much flex in the front frame on a lift we have more problems than we want. I will loosen and retorque the bolts for GP's on ramps this weekend. It was cold this morning (30 degrees) I'll take my car for a cruise now that it in the mid 40's to see if there's a difference.

Jays Mustang · 03-29-2007, 05:27 PM

Hey Guys, Once I got off the hill and filled the tank I did a quick cruise 50+ mph and the noise is better. But once slow again under 35 mph it kicked in but not as bad. Almost liveable. Maybe if it was 70 degrees out even better.I was thinking about Sandy and others said about shock replacement. Back in the fall to spoke with Bilstein and explained the whole problem and they felt it was a bad designed strut. Bad rebound I think they said. Now this was in the early stages of trying to figure this out and wrote it off to them just trying to sell some struts. But now that were getting farther into it and more people are coming forward, it could be something to concider. I know there have been a few on this thread that said about strut replacement and cured the noise. I think we all can agree the upper mount sucks from looking at that video but maybe we need better struts (non-Ford) to help with our problem. What do you guys think?

casperorr · 03-29-2007, 06:13 PM

I am sorry for your bad news James. I just returned from my dealer, I was picking up my front bra that I ordered. Anyway, I got a chance to talk to the service manager and told him about our latest on the front suspension noise. I explained what I did to get rid of the noise, and that others were trying the same part install. He added that with the low milage and interstate driving in my Mustang that it could be very possible that I got lucky and installed my bar before possible damage was created in other areas, (ie. strut mount and bearings, etc. etc..). After talking to him for some time concerning our on going struggle with this noise, he believes that it is a combination of front suspension failure, and not limited to just one part. He is not very impressed with Ford's front end on the Mustangs. Being an owner of a Mustang in his youth, driving around a 1967, He claims that compared to the old engineering in earlier Mustangs, our new ones might as well be made of plastic. Depending on the quality of the roads in your area, along with the amount of time and miles driven on different terrian, there will be many different outcomes. And the fact that there is no paticular pattern to everyone's "noise and/or fix" , leads him to believe it is not one item rather than the complete design or the front suspension.
Well I am sure I don't need to tell you how I felt when I left the dealership. The fact that my noise is gonefor now is notexactly great news anymore if what my service manager had to say is true. I hope that Ford is taking this serious and does have a fix coming in the nextTSB.
I am sorry my friends for getting everyone's hopes up with this fix. I know how important it is to all of us.
I feel for you and your bank account, for I do know the stress and expense of our problem. And there is some of you that have given greatly to the expense side of this troubleshooting game.
I will continue to troubleshoot the noise problem, andwill assisteveryone where I can.
Don't give up, Keep smiling my friends,

Casper

Jays Mustang · 03-29-2007, 07:44 PM

Thanks Casper, That sounds like an honest Service Manager. I agree about suspension design, I'm from the old days and front frames were a lot stronger back then. I wonder if they make them like crap now for crumpling up in front end collisions. Whatever the reason, it sucks. Your thoughts are correct too. We probably need more than one part to correct our problem. Now I got more to think about.

wolfey2k · 03-30-2007, 02:22 AM

Just a note you guys.
The second quarter we have all been waiting for begins in a couple of days.
Remember, I was told a couple months ago that the TSB will be out late March to mid April.
Let's see what happens.
Jay, you're driving me nuts now ;-D.

Wolfey2k