Front end clunk/rattle

[22SporTsploder]

There is a service bulletin about defective front struts on certain 2023 Explorers. I replaced my front struts, rear shocks and all end links and hardware at 2000 miles on my own dime and had them installed as part of installing H&R lowering springs. That fixed the low speed clunking and its never came back in 6000 additional miles. This was before the SSM came out.

View attachment 26415

Yea I have 22 with a 01/22 build date but I will go ahead and make an appointment especially since I have an extended warranty. Thanks for posting this. Glad to know its not just me hearing the sounds.

 

[Nompgx3]

We bought a 23 st in October it’s at 3500 miles now, in the last 1000 miles we have heard a rattle at low speeds and when you hit bumps. It’s not consistently doing it. It doesn’t sound rough or like it’s damaging anything, but it’s a bit annoying. Anyone experienced this?

We bought a 23 st in October it’s at 3500 miles now, in the last 1000 miles we have heard a rattle at low speeds and when you hit bumps. It’s not consistently doing it. It doesn’t sound rough or like it’s damaging anything, but it’s a bit annoying. Anyone experienced this?

I have a 24 ST just turned 3500. It has the clunking noise it sounds like the drivers side. It seems to be getting louder as the days go on. I have him scheduled to go in Wednesday at 10 for them to look at it. I guess i need to put on my boxing gloves when I get there huh? I haven't seen any 24's post with this problem, unless I'm looking in the wrong place.

 

[enphor]

Welp add my 24' with 1800 miles to the list of wierd rattle clunking noise seemingly coming from the front. Starts at low speed , even when the road is not bumpy. I try braking, accelerating, putting in neutral and idling, etc. seems to be there no matter what. The ST handles great and no apparent negative feedback whatsoever, but its annoying as hell. I guess I'm due to take her in. Can't wait for the dealership to tell me "its your mods"

 

[enphor]

I have a 24 ST just turned 3500. It has the clunking noise it sounds like the drivers side. It seems to be getting louder as the days go on. I have him scheduled to go in Wednesday at 10 for them to look at it. I guess i need to put on my boxing gloves when I get there huh? I haven't seen any 24's post with this problem, unless I'm looking in the wrong place.

Did you get yours diagnosed and fixed?

 

[22SporTsploder]

Yea I have 22 with a 01/22 build date but I will go ahead and make an appointment especially since I have an extended warranty. Thanks for posting this. Glad to know its not just me hearing the sounds.

I took mine in which was my first trip to the dealer and what a great experience. My rep took the vehicle in diagnosed and they will be replacing both front struts under warranty. They said they were loose and needed replacement. The left strut was on backorder until the 27th the right is already waiting at the dealership. I'll take it in once the call to have both replaced. What I did was put the TSB number I got from someone posting it here which was actually for the 21 model and I have a 22, on the service request. I wanted them to look right at the issues the TSB pointed out and it worked with out a problem.

 

[22SporTsploder]

Welp add my 24' with 1800 miles to the list of wierd rattle clunking noise seemingly coming from the front. Starts at low speed , even when the road is not bumpy. I try braking, accelerating, putting in neutral and idling, etc. seems to be there no matter what. The ST handles great and no apparent negative feedback whatsoever, but its annoying as hell. I guess I'm due to take her in. Can't wait for the dealership to tell me "its your mods"

I asked my dealer about mods because I have eibach springs I'm installing and they said any mod I install they would have to be able to prove that the mod caused the issue you are having and in most cases that's hard to do so you should be good with mods just use your discretion.

 

[enphor]

My ST is at the dealer now for this low speed front end clunking. Under 2000 miles . They said the tech "foreman" personally took it for a test drive and heard the noise. They are supposed to get back to me Monday with what the issue is and the resolution. Since I haven't touched anything related to suspension mod-wise I can't see how they'd blame my mods for whatever it is. I gave them the 23' strut TSB to look at and its noted on the shop form.

 

[22SporTsploder]

My ST is at the dealer now for this low speed front end clunking. Under 2000 miles . They said the tech "foreman" personally took it for a test drive and heard the noise. They are supposed to get back to me Monday with what the issue is and the resolution. Since I haven't touched anything related to suspension mod-wise I can't see how they'd blame my mods for whatever it is. I gave them the 23' strut TSB to look at and its noted on the shop form.

Nice keep us posted on the outcome!

 

[enphor]

Dealership just reached out. They stated that both front struts and possible strut mounts will need to be replaced. They say the parts should arrive tomorrow. Pretty shocked that they'd have them that quick, we'll see!

 

[22SporTsploder]

Dealership just reached out. They stated that both front struts and possible strut mounts will need to be replaced. They say the parts should arrive tomorrow. Pretty shocked that they'd have them that quick, we'll see!

Sweet mine is going in on Thursday they finally got all the parts. I can't remember if they said my mounts had to be replaced too I'll be asking about that. Hope yours comes in quickly!

 

[enphor]

Just got the ST back from the dealer. Great service from Mark Ficken Ford in Charlotte. Dropped it off Friday AM, picked it up Monday afternoon all fixed. It was indeed the front struts similar to the MY23 TSB posted earlier in this thread. I'm betting Ford has a stash of "potentially bad" shocks and its cheaper to deal with warranty claims versus going through each one trying to find out which are bad? They stated "excessive wear". The vehicle has under 2K miles on it! Definitely a defect or incorrect factory installation.

Here's the parts breakdown according to the invoice, all covered under warranty.

Cause: EXCESSIVE WEAR
Correction: TEST DROVE VEHICLE, VERIFIED CONCERN, USED CHASSIS EARSFOUNDNOISE TO BE
ONLY OVER BUMPS AND AROUND BOTH STRUTS WENT TOPINPOINT BFRONT BOTTOMING OR
RIDING LOW, B1 MEASURE RIDE HEIGHT FOUNDRIDE HEIGHT TO BE WITHIN SPEC, B2 CHECK FOR
DAMAGED OR WORNSTRUTS, FOUND EXCESSIVE WEAR IN BOTH FRONT STRUTS AND
STRUTHATS, REPLACED BOTH FRONT STRUTS AND STRUT HATS RETEST DROVECAR VERIFIED
REPAIR, CHECKED CAMBER ON ALIGNMENT RACK

Part Number Part Description Parts Total: $ 0.00
FOLB5Z-18124-B SHOCK ABSORBER
FOLB5Z-18124-K SHOCK ABSORBER
FO-W715932-S439 BOLT
FO-W520517-S440 NUT - HEX.
FO-W721102-S439 BOLT AND WASHE
FOLB5Z-3A197-A MOUNTING ASY
FO-W719506-S440 NUT - BLIND AN
FO-W714660-S439 BOLT - HEX.HEA
FO-W520115-S440 NUT - HEX.

 

[22SporTsploder]

Just picked up my 22 and they only replaced the left since the right wasn't making any noise. I'm on an extended warranty so I don't feel like I got as thorough of a experience as @enphor but they did replace the left strut and bolt. But I don't hear any clunking or rattles so if I do it will go back obviously. Time to install the eibach springs and spacers, can't wait.

 

[enphor]

Something is obviously messed up for struts and mounts to be failing for me only after a few thousand miles. And even for others with under 100k miles and only a few years old. Maybe it was a batch of covid struts still in circulation lol.

 

[23 Explorer ST]

Something is obviously messed up for struts and mounts to be failing for me only after a few thousand miles. And even for others with under 100k miles and only a few years old. Maybe it was a batch of covid struts still in circulation lol.

My 23 did this in the first 2k miles since new. 11k on it now.
Finally have an appointment Thursday to have both replaced.


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[enphor]

My 23 did this in the first 2k miles since new. 11k on it now.
Finally have an appointment Thursday to have both replaced.


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What a joke, do better Ford!

 

[bhunted1]

I’m starting a case with Ford to contact the dealer. Dealer cannot hear or find the rattle. Yet, I hear it as plain as day. They wont replace anything if they cant find the noise. They’ve done a 24 with the same issue. I’m not dropping off the vehicle again just to have them say they cannot find the prob.
So either Ford steps on their toes or buy it back. Then Im done with Ford.
Decades of Fords under my belt and their crap over the last several years has burned me out.
Just cannot take it anymore.
They have to fix the moonroof shade which wont calibrate and Ive replaced almost all fastners for that damn liner under it. I even replaced the cross over bar. Ive updated all modules firmware. Never an ota. Mirrors were closing when they were set not to.
Brand new vehicle and its been a pain in the arse.
Sorry for the rant but Ford is off their rockers.
I had 5 Grand Cherokees in a row. Never an issue.




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[enphor]

I’m starting a case with Ford to contact the dealer. Dealer cannot hear or find the rattle. Yet, I hear it as plain as day. They wont replace anything if they cant find the noise. They’ve done a 24 with the same issue. I’m not dropping off the vehicle again just to have them say they cannot find the prob.
So either Ford steps on their toes or buy it back. Then Im done with Ford.
Decades of Fords under my belt and their crap over the last several years has burned me out.
Just cannot take it anymore.
They have to fix the moonroof shade which wont calibrate and Ive replaced almost all fastners for that damn liner under it. I even replaced the cross over bar. Ive updated all modules firmware. Never an ota. Mirrors were closing when they were set not to.
Brand new vehicle and its been a pain in the arse.
Sorry for the rant but Ford is off their rockers.
I had 5 Grand Cherokees in a row. Never an issue.




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Tell them to use chassis ears, my dealer noted that is what they used. Its a remote setup where they place microphones at strategic locations and can listen on earphones in the vehicle while driving. Plus its kinda freaking obvious the clunking sound like marbles banging around.

That being said, yea they need to do better. This isn't a bottom of the line trim model and extra effort at a minimum should be put into QA for both the parts and factory assembly.

 

[bhunted1]

Tell them to use chassis ears, my dealer noted that is what they used. Its a remote setup where they place microphones at strategic locations and can listen on earphones in the vehicle while driving. Plus its kinda freaking obvious the clunking sound like marbles banging around.

That being said, yea they need to do better. This isn't a bottom of the line trim model and extra effort at a minimum should be put into QA for both the parts and factory assembly.

They claim they did use the ears. I had a svc manager in vehicle with me and he
heard nothing.
I’m giving them one more chance to fix this.
Then Im filing a complaint with Ford. Its 50 miles round trip. Its a pain getting there with no ride. They keep the effing thing a whole day and call they cant find anything. Its nuts!


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[enphor]

They claim they did use the ears. I had a svc manager in vehicle with me and he
heard nothing.
I’m giving them one more chance to fix this.
Then Im filing a complaint with Ford. Its 50 miles round trip. Its a pain getting there with no ride. They keep the effing thing a whole day and call they cant find anything. Its nuts!


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Force them to inspect the struts and top mounts if you can.