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SUBJECT: Rattle/knocking Sound From The Front Suspension OVERVIEW: This bulletin involves replacing the front sway bar bushings at the frame. SYMPTOM/CONDITION: The vehicle may exhibit a rattle/knocking sound which may be heard at low speeds while driving over bumps and/or road surfaces with minor fluctuations. REPAIR PROCEDURE: 1. Replace both front sway bar bushings at the frame. Refer to the detailed removal and installation procedures available in TechCONNECT, under: Service Info, 2 – Suspension, Front, Bushings, Removal and Installation.

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ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front pneumatic failure) or C1726 (air suspension rear pneumatic failure). ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies, even if they have not detached from the ball stud.Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL LINKAGES FOR THE SERVICE REPAIR. 1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM), Section 204-05. 2. Discard the old linkage arms.

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COMPONENT: Suspension: Front: Wheel Bearing POTENTIAL NUMBER OF UNITS AFFECTED^86333 I SUMMARY: On certain pickup trucks, the front wheel bearing may have received an insufficient quantity of grease during the manufacturing process. CONSEQUENCE: This could result in bearing degradation, and if subsequent noise and vibration are ignored, could result in hub assembly separation. This may result in a loss of vehicle control

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Removal Procedure Warning: Refer to Brake Dust Warning (See: Service Precautions\Technician Safety Information\Brake Dust Warning). 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (See: Maintenance\Vehicle Lifting\Service and Repair). 2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation (See: Maintenance\Wheels and Tires\Service and Repair). 3. Remove the wheel speed sensor. Refer to Front Wheel Speed Sensor Replacement (AWD) (See: Sensors and Switches – Brakes and Traction Control\Wheel Speed Sensor\Service and Repair\Front Wheel Speed Sensor Replacement)Front Wheel Speed Sensor Replacement (RWD) (See: Sensors and Switches – Brakes and Traction Control\Wheel Speed Sensor\Service and Repair\Front Wheel Speed Sensor Replacement). 4. Remove the front wheel bearing and hub assembly. Refer to Front Wheel Bearing and Hub Replacement (AWD) (See: Maintenance\Wheels and Tires\Wheel Bearing\Service and Repair\Front Suspension)Front Wheel Bearing and Hub Replacement (RWD) (See: Maintenance\Wheels and Tires\Wheel Bearing\Service and Repair\Front Suspension). 5. Remove the front brake shield (1). Installation Procedure

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Several different front calipers are used on EuroVan. Calipers can be identified by the PR number on the vehicle identification plate. See Fig. 1 . See FRONT BRAKE CALIPER IDENTIFICATION . FRONT BRAKE CALIPER IDENTIFICATION PR Number (1) Caliper Model 1LU (2) FN3 1LP (2) Lucas C54 1LE (2) Lucas RC54 1LB (3) FN3 Or FNR (1) Identify brake version by reading PR number on vehicle data plate. Data plate is located on left “A” pillar, next to central electronics. See Fig. 1 . (2) Used with 15″ wheels. (3) Used with 16″ wheels. NOTE: On vehicles with knee padding, vehicle data plate is located under central electric cover (under driver’s side of dash).