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Topic: FYI- Goose chase to fix strange noise-Long! (Read 5 times) previous topic - next topic
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FYI- Goose chase to fix strange noise-Long!
Yahoo Message Number: 56262
A couple of weeks ago I posted here asking for any  V-10 Ford Techie's help to solve a strange noise problem I was having with our 2001 IB LD with only 16,000 miles on it.I only received two kind suggestions that didn't solve the problem.
Soooooooooo, I began my goose chase.
Only after two eight hour days-175 miles- going to 5 (yes- 5 )Ford dealerships, and 3 independent shops , many phone calls ( including Fords motorhome assist #),and 3 Ford parts houses,I finally solved the MYSTERY noise! Wow! What a goose chase! I could only think of, what if this had happened in some remote town instead of Denver, Co.? Perhaps this noise was only unique to our HaRVey #2 LD? You might want to save this post just in case this happens to your beloved LD? ( save your stressnodes also!) The noise was a loud scraping-whirring-hissing-dry bearing like noise coming from the engine area, on the passenger side when excelerating hard, after reaching higher RPM,s. It would also make the sound when sitting if you would rev the engine fairly hard.
I had many people guess, any thing from a $500 fan clutch job, down to many "boy, I don't know's",and "Wow!, that's not normal" It was quite concerning, as it was quite loud at times.
To make a long story longer---I finally bumped into a rather groady greasy (probably hard working) mechanic. That had to hear the sound for only about 2 seconds and proclamed he new exactly what was causing the noise.(he was right!) Two weeks before , he had spent two and a half days trying to solve the same noise on SOB motorhome. That poor dude(or dude-et) had to pay around $350 to fix what I fixed myself, for $12.52 and 20 min. time, after my hero mechanic solved my Mystery sound for me and didn't even charge me a thin dime. (perhaps he belongs to the LD cult?) To make a long story even longer ---(I'm sure buy now you are eather snoring or on the edge of your seat dying for the punch line).
Walla! There is a small plastic flow restrictor in one of the heater hoses that with heat and high RPM's dislodges from its original position and moves up the hose until it stops at the heater core inlet tube.
(bottom tube)At high RPM's it vibrates and chatters against the heater inlet tube making this loud grinding like sound , driving any insane person, insaner! After 3 Ford parts suppliers, and a perstant counter person and 30 min. of searching on computer, catalogs, and more phone calls, my next hero found the correct hose to solve the problem. Thank goodness the Ford guys changed the placement of the restrictor in the hose and put a clamp on it, to prevent it from moving up the hose. I'm amazed this isn't on any recall lists and Ford failed to inform at least 4 dealerships in the Denver area of the problem? My parts hero, felt so sorry that I had been on such a goose chase that he gave me the hose at the dealer price, rather than the $25 to $60, I was quoted at other suppliers.
After removing the air filter housing and loosening the oil filler tube, it was fairly easy to change. A seasoned mechanic probably could change it in 10 min. or less. One end has a strange plastic squeeze clip that I had to study awhile on the new hose.(be careful to not loose the 2 O-rings and plastic ring).
The problem with the parts supliers is that the correct hose doesn't show up on a 2001, but the 2002 is the correct hose.(perhaps I have an early 2002 engine or something?) The correct magic Motorcraft part # is KH-310.
Sorry this is soooo-long, but hope it might save some pain for someone?

Dan Hillman