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TSB 5-9-11 Front End Popping Noise

FORD: 2005 Mustang

ISSUE:
Some 2005 Mustang vehicles built before 4/8/2005 may exhibit an intermittent popping noise from the front of the vehicle while turning left or right. The noise will typically occur during low speed maneuvers and may occur multiple times while turning.

ACTION:
On both sides of the vehicle, install a revised upper strut bearing assembly. If the vehicle was built before February, 2005 it may also be necessary to install a lower spring seat isolator if one is not already present. Refer to the following Service Procedure.

SERVICE PROCEDURE

Remove the strut and spring assembly. Refer to Workshop Manual Section 204-01.
Disassemble the strut and spring assembly.
If the springs do not have a rubber isolator on the bottom spring coil, install isolators. Clean off any dirt prior to installing the isolator. The isolator should be installed 4" (100 mm) from the end of the coil (Figure 1).

Reassemble the strut and spring. During reassembly, make sure the lower spring coil is butted up against the lower spring seat on the strut and the upper spring coil is butted up against the upper bearing assembly.
NOTE: INSTALL ALL NEW FASTENERS DURING REASSEMBLY.

NOTE: VEHICLE ALIGNMENT IS NOT REQUIRED AFTER THIS REPAIR.