Noise, Vibration & Harshness: Other Ford Econoline E150

Vibrate Software(R)

Vibrate Software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate Software(R) calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate Software(R) helps diagnose a vibration concern

1. Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations.
2. Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
3. Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (RPM) and the engine RPM on the worksheet graph. The point on the graph where the vibration frequency (RPM) reading and the engine RPM reading intersect indicates the specific component group causing the concern. An EVA or equivalent tool capable of measuring vibration frequency and engine RPM will be needed.
4. Provide pictures of diagnostic procedures to aid in testing components.

Combination Engine EAR/Chassis EAR

An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The Chassis EARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings.

Engine EAR Basic Unit

An electronic listening device used to detect even the faintest noises. The Engine EARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The Engine EAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds.

Ultrasonic Leak Detector

The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency.

Tracing Powder

Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Carry out the tracing powder test as follows

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1. Clean the weatherstrip.
2. Spray the tracing powder on the mating surface only.
3. Close the door completely. Do not slam the door.
4. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip.

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Index Card

Place an index card or a piece of paper between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the index card or paper after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as it is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment.

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To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out.

To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis.

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1: Customer Interview

The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions

1. When was it first noticed?
2. Did it appear suddenly or gradually?
3. Did any abnormal occurrence coincide with or proceed its appearance?

Use the information gained from the customer to accurately begin the diagnostic process.

2: Pre-Drive Check

It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.

The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road.

4: Verify the Customer Concern

Verify the customer concern by carrying out a road test, an engine run-up test, or both.

The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain RPM. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly.

Vehicle Cold Soak Procedure

To carry out this procedure, proceed as follows

1. Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine RPM. Monitor the vibration/noise duration with a watch for up to three minutes.
2. Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-8 hours.
3. Before starting the engine, conduct a visual inspection under the hood.
4. Turn the key on, but do not start the engine. Listen for the fuel pump, anti-lock brake system (ABS) and air suspension system noises.
5. Start the engine.
6. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or Engine EAR.
7. Refer to «IDLE NOISE/VIBRATION»(ref-221745-S12068676192006022400000) in the Symptom Chart to assist with the diagnosis.

6: Check TSBs/Repair History

After verifying the customer concern, check for TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information.

If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults.

Operating Condition - Vehicle is Not Moving

1. Static operation Noise occurs during component/system functioning. GO to «SYMPTOM CHART - SQUEAK AND RATTLE»(ref-221745-S21552963842006022400000) .
2. While cranking Grinding or whine, differential ring gear or starter motor pinion noise. GO to «SYMPTOM CHART - ENGINE NOISE/VIBRATION»(ref-221745-S38757868632006022400000) . Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to «SYMPTOM CHART - SQUEAK AND RATTLE»(ref-221745-S21552963842006022400000) . Vibration. Acceptable condition.
3. At idle Idle noise. GO to «SYMPTOM CHART - IDLE NOISE/VIBRATION»(ref-221745-S12068676192006022400000) . Idle vibration or shake. GO to «SYMPTOM CHART - IDLE NOISE/VIBRATION»(ref-221745-S12068676192006022400000) .
4. During Gear Selection Vehicle parked on a steep incline. Acceptable noise. Vehicle parked on a flat surface. GO to «SYMPTOM CHART - Driveline Noise/Vibration»(ref-221745-S42826277332006022400000) . Vehicle with a manual transmission. GO to «SYMPTOM CHART - TRANSMISSION (MANUAL) AND TRANSFER CASE NOISE/VIBRATION»(ref-221745-S11321558592006022400000) .

Operating Condition - Vehicle is Moving

1. Depends more on how the vehicle is operated Speed related Related to vehicle speed Pitch increases with vehicle speed. GO to «SYMPTOM CHART - TIRE NOISE/VIBRATION»(ref-221745-S27414234262006022400000) . Noise occurs at specific vehicle speed. A high-pitched noise (whine). GO to «SYMPTOM CHART - DRIVELINE NOISE/VIBRATION»(ref-221745-S42826277332006022400000) . Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to «SYMPTOM CHART - Driveline Noise/Vibration»(ref-221745-S42826277332006022400000) . A low-pitched noise (drumming). GO to «SYMPTOM CHART - ENGINE NOISE/VIBRATION»(ref-221745-S38757868632006022400000) . Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to «SYMPTOM CHART - TIRE NOISE/VIBRATION»(ref-221745-S27414234262006022400000) . Noise varies with wind/vehicle speed and direction. GO to «SYMPTOM CHART - AIR LEAK AND WIND NOISE»(ref-221745-S22165664552006022400000) . Related to engine speed. Noise varies with engine RPM. GO to «SYMPTOM CHART - ENGINE NOISE/VIBRATION»(ref-221745-S38757868632006022400000) . Vibration occurs at a particular speed (mph) regardless of engine speed (RPM). Acceleration Wide open throttle (WOT) Engine induced contact between components. Inspect and repair as necessary. Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to «SYMPTOM CHART - ENGINE NOISE/VIBRATION»(ref-221745-S38757868632006022400000) . Light/moderate acceleration Tip-in moan. Engine/exhaust noise. GO to «SYMPTOM CHART - ENGINE NOISE/VIBRATION»(ref-221745-S38757868632006022400000) . Knock-type noise. GO to «SYMPTOM CHART - ENGINE NOISE/VIBRATION»(ref-221745-S38757868632006022400000) . Driveline shudder. GO to «SYMPTOM CHART - DRIVELINE NOISE/VIBRATION»(ref-221745-S42826277332006022400000) . Engine vibration. GO to «SYMPTOM CHART - ENGINE NOISE/VIBRATION»(ref-221745-S38757868632006022400000) . Turning noise. GO to «SYMPTOM CHART - STEERING NOISE/VIBRATION»(ref-221745-S03904828892006022400000) . Braking Clicking sound is signaling ABS is active. Acceptable ABS sound. A continuous grinding/squeal. GO to «SYMPTOM CHART - BRAKE NOISE/VIBRATION»(ref-221745-S28719434822006022400000) . Brake vibration/shudder. GO to «SYMPTOM CHART - BRAKE NOISE/VIBRATION»(ref-221745-S28719434822006022400000) . Clutching A noise occurring during clutch operation. GO to «SYMPTOM CHART - TRANSMISSION (MANUAL) AND TRANSFER CASE NOISE/VIBRATION»(ref-221745-S11321558592006022400000) . Vibration. GO to «SYMPTOM CHART - TRANSMISSION (MANUAL) AND TRANSFER CASE NOISE/VIBRATION»(ref-221745-S11321558592006022400000) . Shifting Noise or vibration condition related to the transmission (automatic). GO to «SYMPTOM CHART - Transmission (Automatic) Noise/Vibration»(ref-221745-S33412777892006022400000) . Noise or vibration related to the transmission (manual). GO to «SYMPTOM CHART - TRANSMISSION (MANUAL) AND TRANSFER CASE NOISE/VIBRATION»(ref-221745-S11321558592006022400000) . Engaged in four-wheel drive. GO to «SYMPTOM CHART - TRANSMISSION (MANUAL) AND TRANSFER CASE NOISE/VIBRATION»(ref-221745-S11321558592006022400000) . Cruising speeds Accelerator pedal vibration. GO to «SYMPTOM CHART - ENGINE NOISE/VIBRATION»(ref-221745-S38757868632006022400000) . Driveline vibration. GO to «SYMPTOM CHART - DRIVELINE NOISE/VIBRATION»(ref-221745-S42826277332006022400000) . A shimmy or shake. GO to «SYMPTOM CHART - TIRE NOISE/VIBRATION»(ref-221745-S27414234262006022400000) . Driving at low/medium speeds A wobble or shudder. GO to «SYMPTOM CHART - TIRE NOISE/VIBRATION»(ref-221745-S27414234262006022400000) .
2. Depends more on where the vehicle is operated Bump/pothole, rough road or smooth road. GO to «SYMPTOM CHART - SUSPENSION NOISE/VIBRATION»(ref-221745-S39117396612006022400000) . Noise is random or intermittent occurring from road irregularities. GO to «SYMPTOM CHART - SQUEAK AND RATTLE»(ref-221745-S21552963842006022400000) . Noise or vibration changes from one road surface to another. Normal sound changes. Noise or vibration associated with a hard/firm ride. GO to «SYMPTOM CHART - SUSPENSION NOISE/VIBRATION»(ref-221745-S39117396612006022400000) .

Pinpoint Tests

The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. Reinstall all components after verifying system operation is normal.

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Idle Air Control (IAC) Valve

1. Open the hood.
2. Verify the condition by operating the vehicle for a short time.
3. Inspect the IAC valve. If physical evidence of contamination exists, install a new IAC valve.
4. While the noise is occurring, either place an EngineEAR probe near the IAC valve and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the IAC valve is making the noise, install a new IAC valve.
5. Test the vehicle for normal operation.

Checking Tooth Contact Pattern and Condition of the Ring and Pinion

There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch.

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1. Raise and support the vehicle.
2. Drain the axle lubricant. REFER to «REAR DRIVE AXLE/DIFFERENTIAL - DANA 60 & 70»(ref-212588) , «DRIVE AXLE/DIFFERENTIAL - 8.8-INCH RING GEAR»(ref-203345) or «REAR DRIVE AXLE/DIFFERENTIAL - FORD 9.75-INCH RING GEAR»(ref-212085) .
3. Remove the carrier assembly or the axle housing cover depending on the axle type. REFER to «REAR DRIVE AXLE/DIFFERENTIAL - DANA 60 & 70»(ref-212588) , «DRIVE AXLE/DIFFERENTIAL - 8.8-INCH RING GEAR»(ref-203345) or «REAR DRIVE AXLE/DIFFERENTIAL - FORD 9.75-INCH RING GEAR»(ref-212085) .
4. Inspect the gear set for scoring or damage.
5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear.
6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth.
7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always be some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth.
8. A high, thick contact pattern that is worn more toward the toe. Tooth contact pattern shown on the drive side of the gear teeth. The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear.
9. A high, thin contact pattern that is worn toward the toe. Tooth contact pattern shown on the drive side of the gear teeth. The drive pinion depth is correct. Increase the differential ring gear backlash.
10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. Tooth contact pattern shown on the drive side of the gear teeth. The low contact pattern indicates that the drive pinion is installed too deep into the carrier. The differential ring gear backlash is correct. A thicker drive pinion shim is needed.
11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. Tooth contact pattern shown on the drive side of the gear teeth. The pinion gear depth is correct. Decrease the differential ring gear backlash.

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Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine RPM, or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear.

Careful attention must be paid to the tire and wheels. There are several symptoms that can be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the TIRE WEAR CHART to determine the tire wear conditions and actions.

For a vibration concern, use the vehicle speed to determine tire/wheel frequency and RPM. Calculate tire and wheel RPM and frequency by carrying out and following

1. Measure the diameter of the tire.
2. Record the speed at which the vibration occurs.
3. Obtain the corresponding tire and wheel RPM and frequency from the Tire Speed and Frequency Chart. If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire RPM listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40° 10 = 4. Multiply 4 by 105 = 420 RPM. Divide 420 RPM by 60 seconds = 7 Hz at 40 mph.

Tire Speed and Frequency Chart

TIRE SPEED AND FREQUENCY CHART

Brake Disc Machining

SPECIAL TOOL(S)

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MATERIAL

MATERIAL CHART

1. Check wheel bearing end-play and correct as necessary.
2. Remove the tire and wheel assembly.
3. Remove the brake caliper and the brake caliper anchor plate. Refer to «DISC & DRUM»(ref-161514) for the procedure.
4. Inspect the brake linings. Install new brake linings if below specification. For additional information, refer to «DISC & DRUM»(ref-161514) .
5. Measure and record the brake disc thickness. Install a new brake disc if the thickness after machining will be at or below specification. The specification is molded into the brake disc. Do not machine a new brake disc.
6. For vehicles with a two-piece hub and brake disc assembly: Match-mark before disassembly. Remove the brake disc. Clean the hub and brake disc mounting surfaces with metal surface cleaner. Using a die grinder with a mild abrasive (Scotch Brite(R) type), remove any rust or corrosion from the hub and brake disc mounting surfaces. Align the match-marks and reinstall the brake disc on the hub.
7. Using an on-car brake lathe, machine the brake discs. Follow the manufacturer's instructions. After machining, make sure the brake disc still meets the thickness specification.
8. Using the special tools, verify that the brake disc lateral runout is now within specification. For additional information, refer to «BRAKE SYSTEM-GENERAL INFORMATION»(ref-210119) .
9. Remove the special tool hub adapter.
10. Remove any remaining metal chips from the machining operation.
11. For vehicles with a two-piece hub and brake disc assembly: Remove the brake disc from the hub. Remove any remaining metal chips from hub and brake disc mounting surfaces and from the ABS sensor. Apply a liberal amount of lubricant to the hub flange, pilot area and to the brake disc-to-hub mounting surface. Using the match marks, mount the brake disc on the hub.
12. Install the brake caliper anchor plate and the brake caliper.
13. Install the tire and wheel assembly.
14. Test the system for normal operation.

Powertrain/Drivetrain Mount Neutralizing

1. Raise and support the vehicle.
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. Move the vehicle in forward and reverse 0.6-1.2 meters (2-4 ft).
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.

Exhaust System Neutralizing

Note. Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded.

1. Raise and support the vehicle.
2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight.
3. Loosen all exhaust flange joints.
4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress.
5. Tighten the muffler connection.
6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. After neutralization, the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. With the exhaust system installed securely and cooled, the rear hanger should be angled forward.
7. Lower the vehicle.
8. Test the exhaust system for normal operation.

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1. Raise the vehicle until the front tires are off the floor. Make sure the wheels are in a straight forward position.
2. Spin the tire by hand to check the wheel bearings for roughness.
3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing.
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. On vehicles with one sealed bearing, install a new wheel hub.