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Discussion Starter · #1 ·
For a refresher, have a look see here...

http://www.fordmuscle.com/forums/the-garage/soford-dealer-pissed-me-off-warning-long-rant_45746.html?word=rant

Now I dont want this to turn back into a dealer hate thread again, I just want to share some issues Im having with my car.

To start, the most pressing issue was the suspension noise I thought had been fixed last september. During a very hard panic stop on the freeway a few weeks ago, the noise showed up again. This is a loud pop, like metal breaking at a weld.

I had a few other issues, plus I had no time to do an oil change myself, so I sent the car in.

Wife dropped it off just before mothers day for the oil change, restiching of the passenger side seat bottom where a seam was starting to separate, the noise in the suspension, a dangling ebrake cable and a slew of lugnuts I wanted replaced because the chrome covers had come off. As some of you know, without the chrome covers on these cheap lugnuts, it becomes very easy to slip off with your standard 4 dollar chinese star wrench.

I picked up the car myself, and found that the ebrake cable was a special order part, they couldnt duplicate the suspension pop, and they "forgot" about the lugnuts. At least the seat was fixed. Very nice work too, cant tell it was coming apart at all.

Told him I would try and see if I can find a way to duplicate the noise. All I knew was that if I had a full car, and backed over the round curb at my grandmas trailer park, it would "pop out" and that mildy brisk acceleration, like merging with traffic would pop it back into place.

When my card arrived telling me to schedule an appointment, I decided to load the car, pop what ever it was out of place and then proceed to drive like an old lady to the dealer. When I got there I told the service writer to have the mechanic that would be servicing my car to go for a ride with me, as I was sure I could get the noise to happen once.

Dave, the service manager himself, went for that ride. Promptly upon pulling out into traffic, just as expected the noise made its nice loud "pop/crunch" sound and the service managers reply was "I've never heard that before,"

This filled me with confidence. But at least he heard it, and they knew I wasnt some ******* out to try and make up a nonexistant problem, which was they way I was beginning to feel.

That was Tuesday.

This morning, after getting no word, I decided to call and see whats up. I wanted to know exactly what had failed on the car. To my surprise, the operator forwarding the call says "Oh good, they wanted to speak with you" I talked with the service writer, who proceeded to tell me that the noise seemed to have "gone away" and that they drove the car for 30 minutes and couldnt duplicate the noise again.

I flew off the handle. After asking this moron "if ford had somehow found a way that cars cure themselves, why was there stock so freaking low?" I told him to never mind, and that I would be down to speak to someone in person later this morning.

I arrived at about 11:30 and was promptly greeted by the service manager. He told me that while they did indeed fail to duplicate the noise, that they had checked everything under the car, found nothing, but wanted to continue looking. He assured me that they were going to take care of my problem.

I told him to bring out the actual mechanic, and that I would take him for a drive and see what we could do.

This gentlemans name was Bud, and I believe hes a standup mechanic.

We took the car over to an un used side street, and with no other options to load the car, I simply began backing up over the curb. Ten tries later, and setting the ebrake partially to simulate the extra load of a full car, "BANG!!"

The technician responded with a "Wow"

It was then very easy to pull out into traffic briskly and show him how easily it popped back into place. Which it did with an authoritave "BANG"

At this point, I asked him what he thought.....

He told me that he'd not heard it ever before, but that it sounded like the subframe was coming out of the car. We chatted the rest of the way back to the dealership about possible causes, but more and more a subframe issue seemed to fit the bill best.

Fast forward to tonight....

I call up and talk to Dave. HEs busy, but has time to tell me that while they arent sure what the cause is, they've ordered parts!

At this point, where I sit, Im brimming with confidence....

Im going to go down there tomorrow to get a more detailed explanation from Dave, see what parts have been ordered, and with any luck, have a look under the car myself. At this point Im cautiously nervous that the subframe is cracked, and they are gonna try and hack it back together.

Hopefully tomorrow fares better than today.

At least the problem is being addressed, but at this point Im not sure if my car is going to be repaired or totaled.

Has anyone here ever gone through or assisted with a ford buyback for an unrepairable vehicle? Just kinda curious what I may be up against.

On a lighter note, I've been driving a rented Freestyle for 2 days and Im absolutely in love with it. Be it by trade or replacement, Im ditching the Focus for one of these as soon as my home refinance is finished.
 

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Luv, You are always getting screwed when you go to the dealer! I really enjoy reading your "dealer" posts!
I have never heard that kind of a noise either, and the sub having a cracked weld sounds likely... Let us know what goes!

FE
 

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Discussion Starter · #3 ·
Oh I will. I like venting to all you guys
Makes me feel better, and helps keep me from choking the service writer with his own tie.
 

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We had a "popping" problem with our '01 Supercrew when we first got it. Ours was never under load but sometimes leaving a parking lot or something while turning it would pop. Not loud but reminds me now of the idler arm bushing or lack of on the shotrod when I'd leave a curb now and then turning to the right. We took it in and they found nothing and couldn't duplicate the noise. They told us they tightened all the suspenscion parts etc. This was in MD where we bought the truck. As we left the parking lot it did it again.
We get out here to CA and it's still doing it but it wasn't a regular occurance. We decided to take it into the dealer here and see if we had any better luck. Don and one of the mechanics, mechanic driving, took it all over the area, rough roads, potholes the works and it still wouldn't make that noise. He still took it in the garage to look it over and as far as we know they didn't repair or replace anything but to this day it hasn't done it again. They did say the same thing as the dealer in MD did, that they tightened suspencion parts. That was almost 3 yrs ago. So don't know if they tightened the "right" bolt the other shopped missed or maybe it's that the other place told us they tightened things when they actually didn't do anything to it.
Good luck to ya on that Focus. I think I'd be thinking the same thing, time to get some new wheels if finances allow.

Deb
 

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Discussion Starter · #5 ·
What kinda mileage are you getting out of that supercrew deb? Im definately trading up, but I wanna keep my options open.
 

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You know Luv, There is an Ugly Mustng Very Very similar to yours about 5 houses away from me... It's not mooved in a month or two but it could be that the guy who wons it is off to the Desert for a stint... I want that "Uglt, Everywhere you look is a blind spot" Mustang!

FE
 

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Discussion Starter · #7 ·
Well I spoke with the service manager again this morning.

They have no idea what is causing the noise, but they decided to replace the subframe and see if that fixes it. They believe that a cracked weld might be the culprit. We shall see. I've never been one to throw parts at a problem, so Im not exactly thrilled to hear that's whats happening.

I asked what the next step would be if that doesnt fix it, and he had no idea. Im going to get on the phone with Ford's corporate office this afternoon to discuss options. My concern is that I only have 6000 miles of warranty left and we've been chasing this problem since 3 weeks after I bought the car. The service manager discussed possible warranty extensions, but regardless, I am through with this car.
 

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Discussion Starter · #8 ·
Cars not fixed....

Called me said its ready. Replaced the entire subframe, tech couldnt get it to duplicate.

Picked it up, it wasnt. And no there is a slight whirring or whistling noise I think is maybe an exhaust leak. And my clutch smells like a 15 yr old has been riding it all day from testing it.

Now they are going to hook up microphones to the car to determine where its coming from. This is really starting to wear me down.

At least I got the freestyle back before they gave it to anyone else...
 

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Discussion Starter · #10 ·
Im upside down almost $2800.....

I'm in the middle of a house refinance, so I can pay the car off and start fresh. Im really digging this freestyle, but so far the cheapest 06 I've found is still 18k. I want an 06 because the transmission was updated and the tow rating went from 2k lbs to 3500lbs. I dont ever plan on towing, but obviously this means the transmission has gotten better than the frist year run.
 

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I wonder if the floorpan is flexing and "poping" back and forth....kinda like when you lean against a long quarter panel and it pops in, then when you stand back, it pops back out.
Dealing with the dealerships is a sure way to ride the emotional rollercoaster!!
When it comes to classics, I love American cars.....but today, theres no way I'd buy anything American anymore.

<font size=-1>[ This Message was edited by: TorinoStyle2 on 5/26/06 2:19pm ]</font>
 

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Take a 1/2" drive ratchet and extension and hit the sub frame bolts a bit to see if any of them want a little squeese, and LOOK HARD at the washers under the bolt heads, it could be the sub has pulled out through a washer.... Also see if you can move the body of the Rack... I've seen broken rack mounts that were nearly invisible on those things...

FE
 

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I rode the roillercoaster with Ford Motor Company for over a year. Could not get the Lincoln Mark VIII waranty work done correctly. I finally contacted the National Arbitration Board in Washington DC. They contacted Ford and they saw fit to send the Southeastern Factory Service Rep. to check the car. Problem was solved in a hurry.
 

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On 2006-05-25 23:22, Luv70sFords wrote:
I was actually thinking the same thing of the firewall today. Seems very possible at this point.
My dad had a Ranger that cracked the firewall right at the clutch master cylinder. It was well off warrantee by that point so it got a weld and reinforcing plate and was good for another 100K. Your symptoms point more to suspension IMO, but it wouldn't hurt to look at that firewall.
 

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Discussion Starter · #17 ·
Just a small update...

Called today to get a status check. Said they were on a test drive. HAvent heard back. I assume the test drive didnt fare to well.
 

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Discussion Starter · #19 ·
Score a point for the new guy...

ITs fixed. Seems when they checked all the motormounts, they missed one....

I still have a new subframe under the car


Cars still in the shop though, theres a vacuum leak somewhere on the backside of the engine. We tried to find it while I was there, but we werent able to locate it. Looks like I'll be picking up the car Tuesday...
 
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