Engine/Exhaust System - Vibration/Rattle On Acceleration

Article No.
03-20-7

10/13/03

^ ENGINE - 4.2L - VIBRATION AND/OR RATTLE IN
GEAR AT IDLE OR WHEN ACCELERATING FROM A
SLOW SPEED 32 KM/H (20 MPH) - VEHICLES BUILT
BEFORE 2/25/02 EQUIPPED WITH AUTOMATIC
TRANSMISSION ONLY

^ VIBRATION - VIBRATION AND/OR RATTLE IN GEAR
AT IDLE OR WHEN ACCELERATING FROM A
SLOW SPEED 32 KM/H (20 MPH) - VEHICLES BUILT
BEFORE 2/25/02 EQUIPPED WITH 4.2L AND
AUTOMATIC TRANSMISSION ONLY

FORD:
2000-2002 F-150

This article supersedes TSB 03-9-10 to update the Service Procedure.

ISSUE
Some vehicles built before 2/25/02 equipped with the 4.2L engine and Automatic Transmission, may exhibit a Vibration and/or Rattle condition when the engine is at idle in gear or when accelerating from a slow speed 32 km/h (20 MPH). This may be caused by an exhaust vibration condition and may falsely appear to come from the catalytic converter.

ACTION
Verify the condition before replacing any components or before attempting any repairs. If necessary, install Exhaust System Damper(s) and/or Motor Mounts. Refer to the following Service Procedure for details.

SERVICE PROCEDURE

1. Check for Diagnostic Trouble Codes (DTC's). Resolve all codes that are present using the appropriate Powertrain Control/Emissions Diagnosis (PC/ED) Service Manual before proceeding.

2. Correct any looseness, misalignment, or binding in the exhaust system as directed in section 309-00 of the appropriate year Workshop Manual.

3. If engine lift brackets are present, remove and discard them. Ensure the manifold nuts are re-torqued to 23-27 N.m (17-20 lb-ft).

4. Verify the correct engine mount application as follows and correct as needed:

^ A/T engineering numbers YL34-6038-CA (R.H.) & YL34-6B032-AA (L.H.)

^ M/T engineering numb&s YL34-6038-DA (R.H.) & YL34-6B032-DA (L.H.)

NOTE
BOTH ENGINEERING NUMBERS APPEAR ON THE MOUNT BRACKETS. THEY ARE FURTHER IDENTIFIED BY AN ORANGE DOT FOR M/T AND A YELLOW DOT FOR A/T.





5. On 139" wheelbase, install Exhaust System Damper (1L3Z-5G209-BA) in front of the muffler as shown (Figure 1).

6. On 120" wheelbase, install Exhaust System Damper (3L3Z-5G209-BA) in front of the muffler as shown in (Figure 1).

NOTE
IF THE VIBRATION IS STILL PRESENT AFTER THE FRONT DAMPER INSTALLATION (PER STEPS 5 & 6), IT WILL BE NECESSARY TO INSTALL A SECOND DAMPER (3L3Z-5G209-BA) AT THE REAR OF THE MUFFLER AS SHOWN (Figure 1).





Parts Block

OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 03-9-10
WARRANTY STATUS: INFORMATION ONLY





Disclaimer