Service Slants

Ford Truck

Cabin water leak. Owners of 2005-06 Ford Expeditions or Lincoln Navigators may come into your shop one day complaining that the carpeting at the passenger-side footwell area gets very damp or wet every time the air conditioning system is turned on. One likely reason for the leak, says Ford, is that the evaporator drain tube doesn't extend far enough outside the case to allow condensation from the evaporator to exit the vehicle. Installing an elbow connector (Part No. F3LY-6A614-A) onto the tube end should provide just enough of an extension to get the job done.

To install the connector, start by turning off the air suspension switch, if the vehicle is so equipped, then open the hood. On Expeditions, remove the transmission dipstick; on Navigators, make sure the running boards are fully extended. Next remove the right front wheel, followed by the inner fender splash shield. On Expeditions, remove the dipstick tube at the transmission. Using the illustration at right as a guide, remove the push pin that retains the dash panel insulator to the cowl. Now swing the insulator outward to expose the evaporator drain tube behind it, as shown.

Continue by installing the shorter end of the connector into the drain tube so the longer end extends outward and points down toward the ground. Now close the dash panel insulator and secure it to the cowl with the push pin. On Expeditions, reinstall the dipstick tube and dipstick. To make sure the connector is properly installed, start the engine, turn on the a/c and verify that condensation from the case is dripping outside the vehicle. If it isn't, reposition the connector. If it is, reinstall the inner fender splash shield and right front wheel, switch the air suspension system back on (if applicable) and the fix is complete.

GM Truck

Hissing or gurgling noise from interior. Drivers of 2003-06 GM full-size pickups and SUVs (complete list given here) may complain of a hissing or gurgling sound that seems to emanate from the instrument panel. With a little prodding they'll probably tell you that the noise is most noticeable at idle with the a/c compressor engaged, and can continue for five to ten seconds after the compressor disengages or the air conditioning system is turned off.

According to GM, the most likely cause of the noise is the expansion of the refrigerant as it passes through the orifice tube. Installing a new-design liquid line into the a/c system should eradicate the annoyance immediately. Vehicles that are susceptible to the condition are Cadillac Escalades; Chevy Avalanches, Silverados, Suburbans & Tahoes; and GMC Sierras & Yukons. Here are the parts particulars for the new liquid line:

Chrysler

Buzz or rattle in passenger compartment. Chrysler says that some 2005-07 Town & Country and Caravan minivans can give off an irritating buzzing or rattling noise in the interior. According to the carmaker, the problem is limited to vehicles produced between 6/1/04 and 9/5/06, and is most likely due to a tab on the rear quarter trim panel rubbing against the rear speaker grille. The noise can emanate from one or both sides of the vehicle. Cutting off the tab from the panel is the simple fix.

To do it, first remove the left quarter trim bolster that's located just over the speaker. With the bolster off you should see the tab at the bottom front portion of the opening. Grab a tin snips or heavy-duty scissors and cut the tab just below the speaker frame. Reinstall the trim bolster, then repeat the drill at the right rear of the truck and the job is done.

Chevrolet

Idle problems. Owners of 2005-06 Cobalt SS models with the 2.0L Ecotec supercharged inline Four (VIN P) may come into your shop complaining of a low or fluctuating idle speed that occurs immediately after the engine is started, hot or cold. If hooking up your scanner doesn't turn up any DTCs and there are no other driveability issues noted, flashing the PCM with updated software should improve the idle quality substantially. You'll find the new software calibration on TIS2000 version 6.5, which is available either via die Internet or on a CD.

Saturn

Stumble, hesitation, possible MIL illumination. Some 2005-06 Relay minivans with die 3.5L (VIN L) engine may stumble or hesitate at high engine revs (5400 rpm and above). The problem usually surfaces just before an upshift, and may be severe enough to turn on the MIL and store random misfire DTC P0300 in computer memory. According to Saturn engineers, good, oldfashioned valve float is the likely cause for all die symptoms. Installing new-design, beefier valve springs (Part No. 12599294, complete set of 12) should alleviate the condition. Figure about 5.4 labor hours to complete the job.

Saab

Transmission fluid leakage. Some 2006 9-7X sport/utes with the 4L60-E automatic may leak transmission fluid. Saab says the leak is usually quite small, comes from the bellhousing-to-engine interface and is most likely the result of sharp burrs on the torque converter hub oil pump drive slots cutting into the front pump seal. Removing the converter, filing the burrs smooth and replacing the front seal (Part No. 24202535) should seal up the leak permanently.

To make the diagnosis a lot easier, Saab suggests adding a good-quality trace dye to the tranny fluid, driving the vehicle awhile to allow the dye to circulate, then hitting the bellhousing with an ultraviolet inspection lamp. seeing a dye trace dribbling down where the bellhousing meets the engine clues you in that the pump seal needs your immediate attention.

Mitsubishi

Chirp from drive belt. Some 2006 Raider pickup trucks with the 3.7L engine may produce an annoying chirping sound from the accessory drive belt. According to Mitsubishi, the noise usually occurs when the vehicle is traveling slowly with the steering wheel at full lock (such as during parking maneuvers) and is most likely the result of the drive belt slipping on the alternator pulley. Installing a new-design, improved pulley with a built-in overrunning clutch (Part No. 05170529AA) should eradicate the slip and eliminate the chirping noise immediately.

Start the job by disconnecting the battery ground cable and removing the B+ and field wiring connectors at the alternator. Next, remove the two horizontal mounting bolts, followed by the one vertical bolt and remove the alternator from the vehicle. Remove the old pulley from the alternator.

Continue by installing the upgraded pulley onto the alternator, making sure there's enough clearance between it and the alternator housing. If there isn't, install spacers (Part No. 05170528AA) as necessary behind the pulley to provide suitable clearance. Now install the pulley retaining bolt and torque it to 40 ft.-lbs. Reinstall the plastic insulator cap to the pulley, if so equipped. Install the alternator back into the truck, tightening the three mounting bolts to the same 40 ft.-lbs. Reconnect the wiring at the alternator. To complete the fix, install the drive belt, reconnect the battery ground cable, start the engine and check that the drive belt and all the pulleys are aligned. If they're not, add or subtract spacers as required.

GM

Droning noise from engine bay. Owners of 1999-2002 Chevy Cavaliers and Pontiac Sunfires with the 2.2L (VIN 4) engine may come into your shop complaining of a weird droning sound from the engine compartment. After some prodding, you may learn that the noise is most noticeable in higher ambient temperatures, with the engine idling and the a/c on.

One likely cause of the noise, says GM, is the accessory drive belt setting up a natural resonance in the span between the alternator and a/c compressor. Installing a new-design belt made up of a different rubber compound (Part No. 12575450) should cancel out the resonant frequencies and bring welcome relief to your customers.

Ford/Ford Truck

Debris from HVAC vents. Some 2000-05 Ford cars and light trucks (complete list below) may generate snowflakelike debris from the HVAC vents. According to Ford, the cause of the debris is excess brazing flux from the evaporator core. Cleaning the vent ductwork and evaporator core will eliminate the problem immediately. Here's how to go about the job: Start by removing the floor duct trim. Using masking tape, attach the hose of a shop vacuum to the drivers-side floor duct and seal off the remaining ducts with the tape. Now connect a 2-ft. length of vacuum hose to your compressed air blow gun and secure it with a worm clamp. Close all the instrument panel vents, then move the temp control lever to Cold and the mode lever to Floor/Panel. Set your shop air supply to 90 psi (minimum) and turn on the shop vacuum. Open up one panel vent and direct the compressed air down the duct for at least 30 seconds. Close the vent and move on to the next...and so on. Now change the mode selector to Floor/Defrost and direct the compressed air down the defroster duct for at least 30 seconds. Alternate the mode selector between Floor/Panel and Floor/Defrost and repeat the entire cleaning procedure three more times. Turn off the shop vac.

Now move on to the evaporator core. Set the mode selector to Full Floor and the temp lever to Cold. Next, remove the blower motor and turn on the shop vac. Direct the vacuum hose attached to the blow gun into the blower motor opening and begin cleaning the core. Blow it out from top to bottom, then left to right using a slow, sweeping motion. Do this for a minimum of five minutes-the longer the better. Turn off the shop vac.

Reinstall the blower motor and open all the vents. Now start the car, turn on the air conditioning and position the blower setting on Max. Change the mode every 30 seconds or so while alternating the temp lever between Cold and hot. To complete the procedure, disconnect the shop vac hose from the floor duct, reinstall the duct trim, then vacuum the dashboard and upholstery until all residual flakes are removed from the interior.

Vehicles that are prone to the debris and can benefit from the above cleaning operation are 2000-02 Lincoln Town Cars; 2000-05 Ford Expeditions, F-150 pickups & Lincoln Navigators; 2002-05 Ford Crown Victorias and Mercury Grand Marquis; and 2005 Ford Focus models.

Dodge Truck

Pedal pulsation, vibration while braking. Some 2004-05 Durango sport/utes may produce a brake pedal pulsation or a vibration that can be felt through the steering wheel when the brakes are applied, usually at speeds above 50 mph. Excess thickness variation in the front rotors is the most likely cause of the bad vibes.

As for a fix, Dodge recommends cutting the rotors with an on-car brake lathe, installing updated front brake pads and antirattle springs (Part No. 05139733AA) and, finally, checking the lateral runout in both rotors with the wheels installed. What you're shooting for is a runout reading of .001 in. or less, says Dodge.

To do the runout check, mark a wheel stud on the right side of the truck with a dab of paint, then install the wheel. Tighten the nuts in a cross pattern to an initial torque of 75 ft.-lbs., then again to a final of 145 ft.-lbs. (130 ft.-lbs. for aluminum wheels). Now mark the wheel with chalk in the same location as the stud and install your dial indicator so its pointer is positioned on the center portion of the inboard surface of the rotor. Spin the wheel and note the reading on the indicator gauge. If the runout measurement is at or below .001 in., you're done, and you can move on to the left side of the truck. If the runout is more than .001 in., reindex the wheel to the hub one stud at a time until you achieve the desired reading, then again move to the left-side wheel.

Cadillac

Clicking or creaking sound when opening door(s). Owners of 2006-07 CTS, CTS-V or SRX models may complain of an irritating clicking or creaking sound when opening one or more doors with the inside handle. A dry inside latch release lever is the most likely cause of the noise, says Cadillac. Lubing the lever with a special grease (Part No. 89021668) should eliminate the annoyance.

To go about it, start by removing the trim panel from the offending door. Now peel back the water deflector for a clear shot at the lever. Apply the lubricant at the top and operate the lever to allow the lube to work all the way into the latch assembly. Reposition the water deflector, install the door trim panel and the fix is complete.

Nissan

Harsh or delayed shifts, no power. Owners of 1995-99 Sentra and 200SX models with the GA16DE engine may complain of harsh or delayed shifts and/or lack of power when accelerating. A binding wire within the throttle valve cable housing is the likely cause for the driveability woes, says Nissan.

To make a definitive diagnosis, start by checking the adjustment of the throttle valve cable. If it's out of whack, adjust it. If the adjustment is on the money, run the engine until it reaches operating temperature, then shut it down. Now get into the engine compartment and physically check to see if the wire within the cable housing is binding. If it is, replace the throttle valve cable with an updated design (Part No. 31051-31X10).

If the cable wire isn't binding, hook up a gauge and check the transmission's governor pressure. If it's out of spec, replace the governor valve. If the governor pressure is okay, further transmission diagnosis is required.

GM

Clunking sound from steering. Owners of some 1997-2005 GM cars (complete list below) may complain of a loud clunking sound from the steering while making turns or when rotating the steering wheel with the vehicle stationary. According to GM, a stick/ slip situation in the intermediate steering shaft is the most likely cause of the trouble. Lubing the shaft with grease from a special syringe injector that's part of a kit (Part No. 26098237) should quiet the noise in short order.

Start by removing the intermediate steering shaft from the vehicle. Now fully extend the shaft and dispense all the grease from the syringe into the aluminum end of the yoke opening. Grab the rubber plug supplied with the kit and install it into the yoke. Swing the yoke 90° so it presses against the plug, then place the yoke end of the shaft on a workbench. Collapse the shaft as much as possible using a pumping motion. Now remove the plug, slowly pull the two ends of the intermediate shaft apart and make sure at least .200 in. of the splines are covered with grease. To complete the job, stroke the shaft at least 15 times more, then install it back into the vehicle.

The following vehicles are susceptible to the clunking noise and can benefit from the influx of fresh lube: 1997-2005 Chevy Cavaliers and Pontiac Sunfires; 1998-2002 Olds Intrigues; 2000-05 Chevy Impalas & Monte Carlos, and Pontiac Bonnevilles; 2001-03 Cadillac Sevilles and Olds Auroras; 2001-04 Buick Regals; 2004-05 Pontiac Grand Prix models; and 2005 Buick LaCrosses.

Nissan

Chirping noise on 2-3 shift. Some 2002-06 Sentra models with the 1.8L engine and RE4F03B automatic may produce an odd chirping sound just as the transmission upshifts from 2nd to 3rd gear. Nissan says the noise is most obvious on light acceleration (K throttle or less), and is due to internal problems in the high clutch assembly. Adding two 200cc bottles of a special ATF conditioner (Part No. 31003-31X61P) to the box should eliminate the noise immediately.

Note: Start the engine, let the transmission reach operating temperature and check the ATF level before adding the conditioner. If the fluid level is in the hot range on the dipstick, drain about a pint of fluid from the pan to compensate for the conditioner and prevent overfilling and possible shift complaints.

Jeep

Squeak from rear suspension. Drivers of 2005-06 Grand Cherokees or 2006 Commanders (all built before 12/1/05) may complain of a squeaking sound from the rear when the suspension is subjected to rapid jounce and rebound cycles. Jeep has traced the noise to inferior materials used in the rear spring isolators. Replacing all four isolators with an updated design with an improved rubber compound (Part No. 52089341AE, four included) should put an end to the drama.

Pontiac
Hazard flasher stays on. The owner of a 2005-06 GTO may come into your shop one day with a comment that the hazard flasher in his neo-muscle car stays on solid and can't be turned off, even after he repeatedly pushes down on the flasher switch. According to Pontiac, the problem is usually sporadic in nature and caused by a glitch in the internal relay of the body control module (BCM). Updated BCMs are now available to put the issue to rest. Order Part No. 92176590 for 2005 models, 92179694 for 2006 vehicles.

Ford

No transmission engagement. Some 2005-06 Focus models (build dates 4/6705 through 8/16/05) with the MTX-75 manual gearbox may come in on a hook with a complaint of no transmission engagement. When they do, push down on the clutch and try to select a gear. If the shifter feels very light, get under the hood and look at the gearshift cable, because there's a good possibility it's detached from the transaxle, says Ford. Installing a newdesign cable (Part No. 3S4Z-7E395GB) with a better retention system should get your customer up and running again in no time.

Cadillac

Noise from front end when braking or turning. Owners of 2003-06 CTS models may comment on a creaking or squeaking sound from the front suspension when braking or performing slow turns, such as when parking. Cadillac attributes the noise to abnormal contact between the rear bushing on the lower control arm and the outer rate washer. Installing a plastic insulating spacer that's part of a kit (Part No. 19150047) between the bushing and rate washer should take care of the noise in short order.

To make a definitive diagnosis, take the car on a road test and try to duplicate the noise. If you hear the creak or squeak, get the vehicle back to the shop and up on a lift. Now spray the offending rear bushing liberally with water or silicone and get back on the road. If the noise is drastically reduced or eliminated, that's your cue to install the insulating spacer.

Start by removing the lower control arm. Next, use a punch and hammer and remove the rate washer from the rear bushing, then toss it. Now inspect the bushing itself. If you see tears in the rubber, don't proceed any further with this fix; simply replace the entire control arm. If all you see Ls minor scuffing, install the spacer onto the bushing. Next, mount the control arm in an arbor press and drive the new rate washer from the kit into the rear bushing. Reinstall the control arm. Perform the same procedure on the odier side of the car and the fix is complete.

Infiniti

Leaking transfer case. Some 2001-03 four-wheel-drive QX4 sport/utes may lose fluid from the upper left side of the transfer case. A leaking pressure port plug is the likely culprit, says Infiniti. The good news is that a new-design, self-sealing plug (Part No. 31306-2W510) is now available to stop the leak in its tracks. The bad news is that you're going to have to yank the case to install it. After the new plug is installed, run the truck in Drive on a lift for at least five minutes to ensure that the leak has been plugged successfully.

Copyright Hearst Business Publishing Apr 2007
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