ChrisSD Posted November 21, 2009 Report Share Posted November 21, 2009 Nice. Yet another "Quality is Job 1" issue on my car. I had been noticing a nasty squeak coming from the rear right that I couldn't locate by getting underneath and banging around with my rubber mallet. I lubed some bushings too, no effect. This morning I took the wheels off, hooked up my dial indicator, and measured axle runout. Left side was .007", right side was .020", over 2x the max spec. Sigh. Link to comment Share on other sites More sharing options...
Rod_Michel Posted November 21, 2009 Report Share Posted November 21, 2009 Sounds like you received a real lemon, bummer! Any chance that you can get your dealer to thoroughly inspect the car and have required repairs covered under warranty? Nice. Yet another "Quality is Job 1" issue on my car. I had been noticing a nasty squeak coming from the rear right that I couldn't locate by getting underneath and banging around with my rubber mallet. I lubed some bushings too, no effect. This morning I took the wheels off, hooked up my dial indicator, and measured axle runout. Left side was .007", right side was .020", over 2x the max spec. Sigh. Link to comment Share on other sites More sharing options...
ChrisSD Posted November 21, 2009 Author Report Share Posted November 21, 2009 It's definitely under warranty. Will update after I take to a dealer. My car is 100% stock. One day I'd love to mod it, but I need to get to the end of these quality problems first. Once you mod it they'll blame your mods for every failure. Link to comment Share on other sites More sharing options...
DaFreak Posted November 22, 2009 Report Share Posted November 22, 2009 ChrisSD, Make em give you the new painted/finished version of the axle. That might help a little with all the headaches? DaFreak It's definitely under warranty. Will update after I take to a dealer. My car is 100% stock. One day I'd love to mod it, but I need to get to the end of these quality problems first. Once you mod it they'll blame your mods for every failure. Link to comment Share on other sites More sharing options...
Tob Posted November 22, 2009 Report Share Posted November 22, 2009 This morning I took the wheels off, hooked up my dial indicator, and measured axle runout. To clarify, did you pull the rotor and measure the runout on the axle flange itself or did you just check the runout on the rotor? Tob Link to comment Share on other sites More sharing options...
ChrisSD Posted November 22, 2009 Author Report Share Posted November 22, 2009 To clarify, did you pull the rotor and measure the runout on the axle flange itself or did you just check the runout on the rotor? Tob Sorry, flange. Link to comment Share on other sites More sharing options...
ChrisSD Posted December 1, 2009 Author Report Share Posted December 1, 2009 Dealer tomorrow, will update. Hopefully the dealer is perfect like last time. Link to comment Share on other sites More sharing options...
OldSchool Posted December 1, 2009 Report Share Posted December 1, 2009 Dealer tomorrow, will update. Hopefully the dealer is perfect like last time. I had a 1997 Ford Explorer that we ended up getting a whole new rear suspension from Ford. New rear leaf packs and a brand new axle. What was unreal was it took my wife (red head) losing her temper after taking the truck back on 3 seperate occasions. I was absolutely amazed at what she got done. Hopefully you will have an easier time. Good luck. Link to comment Share on other sites More sharing options...
ChrisSD Posted December 1, 2009 Author Report Share Posted December 1, 2009 Dealer verified bent axle, there is one locally in stock. I guess they don't change the whole rear anymore? Part number for right rear is 5R3Z4234A. I guess earlier you could not get the part, Ford must be tired of changing rear ends for an axle! Link to comment Share on other sites More sharing options...
bpmurr Posted December 2, 2009 Report Share Posted December 2, 2009 Dealer verified bent axle, there is one locally in stock. I guess they don't change the whole rear anymore? Part number for right rear is 5R3Z4234A. I guess earlier you could not get the part, Ford must be tired of changing rear ends for an axle! With all the problems you've been having. I'd have their body shop paint it as a courtesy and bill it to Ford. Link to comment Share on other sites More sharing options...
ChrisSD Posted December 2, 2009 Author Report Share Posted December 2, 2009 With all the problems you've been having. I'd have their body shop paint it as a courtesy and bill it to Ford. I am going to ask Ford for a 7/100k bumper to bumper at no charge. I think it is reasonable given what I have had to deal with. Link to comment Share on other sites More sharing options...
ChrisSD Posted December 5, 2009 Author Report Share Posted December 5, 2009 Ugh! Dealer changed right rear axle. The squeak got even worse. I picked the car up so it didn't sit there over the weekend and am bringing it back Tuesday. The dealer is very nice, it isn't their fault Ford's suppliers have turned into complete garbage. This new axle is WORSE than the one they replaced. I took measurements when I got it home due to morbid curiosity: These 2 pics are measuring the disc runout. I put the lugnuts on and torqued evenly to 30 lbs on the disc. PASSENGER REAR: Minimum, 0: Maximum, .023!!! : I took the disc off, and measured it from the flange: Minimum, 0: Maximum, .012!! : For comparison, I measured the driver rear on the disc: Minimum, 0: Maximum, .004: .004 on the disc, don't even need to bother checking the flange on the driver side. I took some pics of the axle mating surface, left side is flush: Right side has some open space, could this be part of the issue? WHAT IS GOING ON FORD??? WHY ARE THERE SO MANY QUALITY ISSUES ON THESE CARS, EVEN WITH ** REPLACEMENT PARTS!!!! ** Link to comment Share on other sites More sharing options...
Torched10 Posted December 5, 2009 Report Share Posted December 5, 2009 Well, thats 2 in a row for rear ends for you, from an SQC viewpoint,that means there must be a heck of alotof rear ends like that on the cars.For those not so well versed,can you tell us what to look for,or listen to to see if we have the same thing.And other than the noise etc, are there driving/safety issues tha may arise--thanks for the post Link to comment Share on other sites More sharing options...
ChrisSD Posted December 5, 2009 Author Report Share Posted December 5, 2009 Well, thats 2 in a row for rear ends for you, from an SQC viewpoint,that means there must be a heck of alotof rear ends like that on the cars.For those not so well versed,can you tell us what to look for,or listen to to see if we have the same thing.And other than the noise etc, are there driving/safety issues tha may arise--thanks for the post You don't have to even try to listen for it. It is loud and obnoxious, you can even hear on the freeway windows up or down. You can't feel it, at least I can't. Just SQUEAK SQUEAK SQUEAK SQUEAK SQUEAK SQUEAK! On the "far" side of the rotation, it bangs into the brake pad. It is a screeching brake sound with no brakes applied, once per revolution and agitated by uneven roads and bumps. You can kill it with the parking brake while driving. I can't think of any safety issues other than the disc heats up due to constant brake application. Link to comment Share on other sites More sharing options...
2010KonaBlueGT Posted December 5, 2009 Report Share Posted December 5, 2009 Ugh! Dealer changed right rear axle. The squeak got even worse. I picked the car up so it didn't sit there over the weekend and am bringing it back Tuesday. The dealer is very nice, it isn't their fault Ford's suppliers have turned into complete garbage. This new axle is WORSE than the one they replaced. I took measurements when I got it home due to morbid curiosity: Did you try indexing your rotor? You may be able to band-aid your squeek until you can get a true axle. Mark one stud and hole. Take the rotor off and rotate it one stud at a time, measuring run-out each time. Find the index that gives you *minimum* run-out, IF you can find one. If the rotor is actually TRUE and the axle is bent, the run-out will be the same with each index but the place where the run-out max is measured should be the same each time (relevent to the marked stud). Did that make sense? Phill Pollard Link to comment Share on other sites More sharing options...
ChrisSD Posted December 5, 2009 Author Report Share Posted December 5, 2009 Yep, I'll try that. Thanks. Link to comment Share on other sites More sharing options...
AgentIan Posted December 5, 2009 Report Share Posted December 5, 2009 You don't have to even try to listen for it. It is loud and obnoxious, you can even hear on the freeway windows up or down. You can't feel it, at least I can't. Just SQUEAK SQUEAK SQUEAK SQUEAK SQUEAK SQUEAK! On the "far" side of the rotation, it bangs into the brake pad. It is a screeching brake sound with no brakes applied, once per revolution and agitated by uneven roads and bumps. You can kill it with the parking brake while driving. I can't think of any safety issues other than the disc heats up due to constant brake application. Chris, Notwithstanding the axle issue, are you sure that this "SQUEAK" isn't just a problem with either the brake pad not moving freely in the caliper, or perhaps the shim between the disk pad and caliper piston? Perhaps all that's needed to alleviate the noise is some light lubrication. Ian Link to comment Share on other sites More sharing options...
ChrisSD Posted December 5, 2009 Author Report Share Posted December 5, 2009 I did inspect the brake caliper and pad and it looked fine. I can always put on that brake lube but after researching this I read through the whole thread in the mods section and that is exactly what I have. All were fixed with correct axles. My runout grossly exceeds maximum specs. Hell of a read: http://www.teamshelby.com/forums/index.php?showtopic=8610 I am so frustrated. This is a brand new car with no mods, and I have been going through hell with it. Ford did a terrible job in the assembly of my vehicle but not only is the assembly bad the actual parts as well. I really want the car but I see no end in sight to these quality problems. It has been in for warranty problems a combined 20 days in the 1st 3 months. If it gets to 30 I have new options. I really feel for the dealer service deparment. How are they supposed to fix cars if Ford ships out bad replacement parts? Seriously, I get a bent axle in my NEW car, then I get a bent replacement part that has WORSE runout than the original? That means there are a lot more bad ones out there. Do I need to spend my own money and purchase new axles of another make? Link to comment Share on other sites More sharing options...
bpmurr Posted December 6, 2009 Report Share Posted December 6, 2009 Chris I feel for you. With all the problems on the car I'd figure some kind of replacement would be in order. What bothers me is that the dealer should have checked this prior to it leaving the shop. What was their explanation? Link to comment Share on other sites More sharing options...
ChrisSD Posted December 6, 2009 Author Report Share Posted December 6, 2009 Chris I feel for you. With all the problems on the car I'd figure some kind of replacement would be in order. What bothers me is that the dealer should have checked this prior to it leaving the shop. What was their explanation? They knew it was still making racket. They just said I could take it home so they could resume next week. They're cool. There is no way Ford would replace the car. Once I get past this HOPEFULLY that is it. Link to comment Share on other sites More sharing options...
Texas Bird Posted December 6, 2009 Report Share Posted December 6, 2009 They knew it was still making racket. They just said I could take it home so they could resume next week. They're cool. There is no way Ford would replace the car. Once I get past this HOPEFULLY that is it. Hi Chris...It seems they installed the axle and parked it without test driving it. Very p*** poor mechanical ethics. I'd mention it to the Service Manager and see how they react. If they roll their eyes at you, I'd find another Ford dealer. Any mechanic worth his salt ALWAYS will test drive the vehicle to be sure the problem is fixed. They teach that in high school auto mechanics classes. Even if you told them not to drive it, someone should have asked to ride with you to ensure the repair. From your pictures there appears to be a gap on the right side that the left doesn't have as you mentioned. Almost looks like something isn't fully seated? You might want to ask them to skim cut the rotor too as this may be amplifying the problem. If there's any rotor warpage it could have well been caused by the out of spec axle. Link to comment Share on other sites More sharing options...
ChrisSD Posted December 6, 2009 Author Report Share Posted December 6, 2009 Hi Chris...It seems they installed the axle and parked it without test driving it. Very p*** poor mechanical ethics. I'd mention it to the Service Manager and see how they react. If they roll their eyes at you, I'd find another Ford dealer. Any mechanic worth his salt ALWAYS will test drive the vehicle to be sure the problem is fixed. They teach that in high school auto mechanics classes. Even if you told them not to drive it, someone should have asked to ride with you to ensure the repair. From your pictures there appears to be a gap on the right side that the left doesn't have as you mentioned. Almost looks like something isn't fully seated? You might want to ask them to skim cut the rotor too as this may be amplifying the problem. If there's any rotor warpage it could have well been caused by the out of spec axle. Thanks for the info! They did test drive it though, then called me to tell me the problem was still there. They also had me down to go for a ride with them. They're doing fine. I just preferred to take the car home instead of leave it there over the weekend. Link to comment Share on other sites More sharing options...
Texas Bird Posted December 6, 2009 Report Share Posted December 6, 2009 Thanks for the info! They did test drive it though, then called me to tell me the problem was still there. They also had me down to go for a ride with them. They're doing fine. I just preferred to take the car home instead of leave it there over the weekend. ROGER...just tryin to help...hope they/you get it lined out. Link to comment Share on other sites More sharing options...
ChrisSD Posted December 16, 2009 Author Report Share Posted December 16, 2009 Dealer replaced axle again, and as a courtesy to ease any of my fears of other parts being affected because of it replaced the caliper and brake linings. All fixed =) Link to comment Share on other sites More sharing options...
6-Speed Posted December 17, 2009 Report Share Posted December 17, 2009 Dealer replaced axle again, and as a courtesy to ease any of my fears of other parts being affected because of it replaced the caliper and brake linings. All fixed =) Glad it all worked out. It's sometimes a painful process, but satisfying in the end. Link to comment Share on other sites More sharing options...
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