Some 2006 Lincoln Zephyrs, 2006-09 Ford Fusions and Mercury Milans and 2007-09 Lincoln MKZs may emit a popping, rubbing or crunching sound from the front suspension when going over bumps or while turning at low speeds.
The most likely cause of the noise, Ford said, is the jounce bumper of the front strut rubbing against the strut plate. Lubricating the bumper with silicone brake caliper grease should eliminate the condition.
Start the fix by putting the vehicle on a lift and removing and disassembling the front strut. Using the illustration, apply the caliper grease around the entire circumference of the upper and lower surfaces of the jounce bumper, as shown.
To complete the repair, reassemble the strut, install it, then repeat the procedure on the other side of the vehicle.
"Factory Fixes" is written by Jim DePalma, a 30-year veteran of the auto repair business who has served stints as a service manager, parts manager and ASE-certified technician. His column provides vehicle manufacturers' authentic factory technical service bulletins (TSBs) that have been condensed for easier reading. Mr. DePalma advises that techs always check with a dealer or repair information system for the latest revisions before starting to work on a vehicle. He can be reached via e-mail at [email protected].