TECHNICAL SERVICE BULLETIN
Body Creak/Pop Noise Over Bumps - Right Front Subframe Bolt Area Built On Or Before 31-Jan-2016

18-2239
13 August
2018

This bulletin supersedes 16-0021. Reason for update: New Part/Procedure For Same Condition
Model:
All
Summary
This article supersedes TSB 16-0021 to update the Service Procedure.
Issue: Some 2016 Explorer vehicles built on or before 31-Jan-2016 may exhibit a pop or creak noise from the right
front mounting bolt of the front subframe. This condition may be due to a mispositioned weld between the barrel nut
and the subframe mounting bracket.
Action: Follow the Service Procedure steps to correct the condition.
Parts
Part Number Description

Quantity

Obtain Locally ValuGard™ Rust Inhibitor, VG-104/VG-104A

1

Obtain Locally ValuGard™ Premium Undercoating, VG-101/VG-101A

1

Warranty Status: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Warranty/ESP coverage
limits/policies/prior approvals are not altered by a TSB. Warranty/ESP coverage limits are determined by the
identified causal part and verified using the OASIS part coverage tool.
Labor Times
Operation
Time
No.

Description
2016 Explorer: Diagnose And Repair The Front Subframe Following The Service Procedure (Do
Not Use With Any Other Labor Operations)

182239A

1.3
Hrs.

Repair/Claim Coding
Causal Part:

16054

Condition Code: 01

Service Procedure
The steps below will add an additional weld to eliminate the possibility of the barrel nut creak/pop noise.
1. Attach Rotunda Wireless Chassis Ears JSP97202 or equivalent to the subframe. Does diagnosis with the chassis
ears indicate the noise is originating from the right front mounting bolt of the front subframe?
(1). Yes - proceed to Step 2.
(2). No - this article does not apply. Refer to Workshop Manual (WSM), Section 100-04 for normal diagnostics.
2. Disconnect the negative battery cable. Refer to WSM, Section 414-01.
3. Remove the right front wheel and tire assembly. Refer to WSM, Section 204-04.
4. Remove the right side fender splash shield. Refer to WSM, Section 501-02.
5. Locate the front subframe bolt mounting tower bracket on the right side frame member and mark 2 cut lines
approximately 63 mm (2.50 in) long as shown. (Figure 1)
Figure 1

6. Using an abrasive cut off wheel, cut the bracket sheet metal along the marked lines. (Figure 2)
(1). Make sure to only cut through the outer layer.
Figure 2

7. Position the sheet metal out of the way to allow access to the barrel nut. (Figure 3)
Figure 3

8. Using a MIG welder, weld the barrel nut to the bracket along the seam. The weld bead should span as far along
the seam as possible. Refer to WSM, Section 501-25 Body Repairs - General Information > General Procedures >
Welding Precautions. (Figure 4)
Figure 4

9. Position the sheet metal back to the original location.
10. Prepare the area for welding by grinding and cleaning.
11. Using a MIG welder, weld the previously cut sheet metal to repair the bracket. (Figure 5)
Figure 5

12. Clean the welded area to prepare it for corrosion protection.
13. Apply ValuGard™ Premium Undercoating or equivalent corrosion protection to the repaired cut line area. Refer to
WSM, Section 501-25. (Figure 6)
Figure 6

14. Apply ValuGard™ Rust Inhibitor or equivalent to the welded barrel nut. Refer to WSM, Section 501-25.
(1). Use an appropriate spray nozzle to access the cavity. (Figure 7)
Figure 7

15. Install the right side fender splash shield. Refer to WSM, Section 501-02.
16. Install the right front wheel and tire assembly. Refer to WSM, Section 204-04.
17. Reconnect the negative battery cable. Refer to WSM, Section 414-01.

© 2018 Ford Motor Company
All rights reserved.
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and
equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information
that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition
described affects your car or truck. Contact a Ford or Lincoln dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy
and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.
The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supersede
this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.