Rattling

[23 Explorer ST]

Triangle piece is the overlapping heat shield that contacts the body if vibrating at high speeds.I am pointing to the clip that was basically off and the bolt near the rear wheel threaded on by two turns. I am also pointing to a location behind mid pipe where bolts were also could be tightened, the pictures are not all inclusive. I suggest you hunt around with a wrench and start tightening everything.

I also examined control arm, sway links, on front right side, nothing appears to be obviously wrong to create a low speed clunk in the passenger front. Even poked around the battery bay, nothing obviously lose.

Thanks for posting this. I kept getting a ticking sound at highway speeds. I checked those bolts and mine was hanging by a thread where it bolts to the heat shield. I tightened it up and all is quiet now.
I have an appointment Thursday at the dealership to deal with the clunking sound from the front end at low speeds.


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[dalethewhale]

At a price point of $60,000 and monthly payments of $700 per month, I would have hoped Ford could have actually built a car that wouldn't fall apart in less than a few years and frustrated owners wouldn't have to get their hands dirty and have to solve problems themselves! Guess it was too much to ask for! It is shameful the number of shortcuts, bad decisions and general bad design and build quality, engineereing/testing or lack thereof. They're gonna get their asses handed to them once China enters this market and I'm a loyal 40 year Ford/Mercury/LIncoln customer!

It's quality assurance, each vehicle make and model has it's own gremlins, it's just by chance your vehicle is perfect. 05 mini cooper s: repeat power steering leaking, wheel bearing, rattles, faulty transmission design; 2018 Murano SL-low speed abs noise for first 5 mins of driving and burning smell at high altitudes (after I almost totaled it in the snow); 2010 prius v: crashes like a like a trash can but otherwise no problems and is not safe; bmw 330 forget the year: repeat noise scratching dashboard and repeat failed navigation replacement; 05 murano - nothing destroyed it or failed after 10 years, 2014 bmw 320 xdrive - nothing failed, souped up and drove it like I stole it everyday, 2020 ford edge st - owned for 3, nothing failed, no issues and tuned it, drove it like I stole it. It's literally by chance if your vehicle is perfect.... I like say Ford Explorer quality assurance is just less than that of other models, and I stepped into knowing this from consumer reports, but the Horsepower, stopping power, cargo space, and driving experience on the road where everybody moves out of the way in the left lane because they think you're a police car, is fantastic.

 

[Suprawill1]

I installed a bigger intercooler, the only step I missed was zip tying the intercooler to the frame because you cut them to install the intercooler. I realized the missed step after buttoning everything up, but the intercooler is also secured by a bunch of bolts. Its just a pain in the ass to unscrew the front bumper bolts. I doubt the missed step is the cause of the sound.

Yes, I had mine installed professionally because I didn't have the garage to do it myself. I def know how long of a process it entails.

The clunk I hear comes from underneath the passenger side, closer to the front suspension.

 

[bhunted1]

The clunk I hear comes from underneath the passenger side, closer to the front suspension.

Same here and they cannot hear it even with their stethoscope gizmo. I hear it just fine.
Driving me nuts!


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[Suprawill1]

Same here and they cannot hear it even with their stethoscope gizmo. I hear it just fine.
Driving me nuts!


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What the flock man! I've had 2 repair shops take an extended look and came up with nothing. We're better off fixing our own vehicles.
Wish I had a lift.
Good luck with yours!

 

[bhunted1]

What the flock man! I've had 2 repair shops take an extended look and came up with nothing. We're better off fixing our own vehicles.
Wish I had a lift.
Good luck with yours!

I don't mind doing some of my own work. But getting old sux. But the fact that -I- can hear and feel it is what really aggravates me. Wife doesn't hear it. I'm at a point that I'm cursed or hearing things.
I posted an ssm awhile back and even gave a copy to the dealer. But they won't do it unless they can prove it.

 

[JCR ST]

...

The clunk I hear comes from underneath the passenger side, closer to the front suspension.

Almost certainly the front passenger side strut... there are a couple of threads about it.

 

[Suprawill1]

Almost certainly the front passenger side strut... there are a couple of threads about it.

I'll have to try and find that. Thanks!

 

[Suprawill1]

I don't mind doing some of my own work. But getting old sux. But the fact that -I- can hear and feel it is what really aggravates me. Wife doesn't hear it. I'm at a point that I'm cursed or hearing things.
I posted an ssm awhile back and even gave a copy to the dealer. But they won't do it unless they can prove it.

At least you're not alone in hearing things.

 

[JCR ST]

I'll have to try and find that. Thanks!

Front end clunk/rattle | Explorer ST Forum

 

[powerboatr]

My 23
Had same loose fasteners on the hybrid battery splash shield.
It also is flimsy and does vibrate.
I put some deadening mat small pieces on the areas the fasteners don't hold it firmly
The shield I was told , was there for air flow etc ..
I see it as a sound tunnel

 

[dalethewhale]

My 23
Had same loose fasteners on the hybrid battery splash shield.
It also is flimsy and does vibrate.
I put some deadening mat small pieces on the areas the fasteners don't hold it firmly
The shield I was told , was there for air flow etc ..
I see it as a sound tunnel

You have photos of this?

I recently tried to reproduce the thunk, it appears at the most random of times. Did everything from cornering, going over speed bumps, hard/slight left/right turns, bad roads, slamming on brakes, etc etc. I almost thinking maybe it was the under body shield making the noise?

I did notice before this, it was more frequently on cold morning starts when car sitting outside (not garage) during the first few blocks only, the exact symptoms to reproduce is difficult and they disappear above 30 mph.

I also notice strut tower bolts and front tower sway bar, could be tightened a little bit more I know most of these parts are universally hand tightening across all makes/models. Keep in mind I am using a 1/4 wrench and only using wrist strength.

 

[dalethewhale]

I think I found the culprit, brain storming on how to fix.

its the flap that recirculates air in the cabin filter that thunks/makes noise. When closed it is silent. When opened it rattles, will test my theory out. It is right where the battery bay is.

Took some pictures on how to get there.

The battery cover is also wobbly and lose could be that.

Will tape around and secure each one to see if it makes a difference.

 

[bhunted1]

Why not try leaving them off and try going for a ride?
I started looking in those areas but it’s been raining.
I can def say it’s not a metallic rattle. Sounds like something soft hitting plastic or something else soft.
A guy on Etsy sells those bolt tabs, (3d printed), that hold up the liner in batches of 20. I want them all batten down first. Found 2 missing and the others quarter way out. Unreal!
They were suppose to be here today but are now mia in the postal system. Usps really messing up lately. Ugh!


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[dalethewhale]

Watch the video, this is what my noise sounds like.

https://youtube.com/shorts/ubEZt1kJiTQ?si=JeAtOJbMoQOLlVf9

 

[bhunted1]

What part is that again? Under the cowl?
Sounds about right. But what confuses me is the inconsistency.

Went back and reread your text. Does it happen when the recirculator is on or off?
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[dalethewhale]

The noise should only occur when the recirculator is off. I need to test it out to validate the idea.

The part is the recirculator flap (and you should see the cabin filter there). You access by removing battery cover plastic, then the cowl screws and clips, then the battery clip on cover, the lift and you should see it behind battery. If there’s a way to disable the actuator it could solve it. I also never want my recirculator disabled/open because SF has sooo many cars and exhaust smell, asian and german cars dont auto disable but some reason the ford does.

 

[bhunted1]

Wonder if you remove filter behind glove box, will you have access to this flap. Hmmmm


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[GomerPyleST]

I don't hear a thing from mine and now I'm wondering if it is even working as my recirculation never stays on. I turn it on and it shows it is closed but then like 5 minutes later it reopens, it likes to randomly open whenever turn it on. ( I know the manual says it can do this but when I turn mine on I like it to stay on just like you I like recirculated air not outside air.) I wonder if yours can be a broken flap control or motor or whatever they call it that makes that thing open and shut? Did ya try taking out the filter and checking it out form the other side?

 

[bhunted1]

Tried getting some stuff done between the rain drops.

- Turned circulator on. Noise still there.
- Turned it off.... noise still there.
- Turned all systems AC/Heat off, etc. Noise still there.
- I actually was able to get my arm/hand behind battery... flap is solid, no movement.
- The whole cowl in front of windshield left to right is solid. No movement.
- Took everything out of glove box and lowered it. Nothing loose. Fuses solid. Filter cover solid, etc. Was going to remove filter cover, but didn't think there was a point being I was able to test it from behind battery.

I really want to get this resolve and hopefully Dale figures out something. I'm rooting for him or anyone that resolves this issue.
OR, I'm back to square one with the right strut being bad.

Not our year but interesting video. Maybe lead to possible ideas in ours.
Ford Explorer front end noise (solved)!