Zephyr V6-3.0L VIN 1 (2006)
Air Register: All Technical Service Bulletins
A/C - Popping From Dash in Defrost Mode
TSB 06-21-12
10/30/06
INSTRUMENT PANEL "POP" NOISE IN DEFROSTER MODE
FORD:
2006 Fusion
LINCOLN:
2006 Zephyr
MERCURY:
2006 Milan
ISSUE
Some 2006 Fusion, Milan, and Zephyr vehicles may exhibit an intermittent popping sound coming from the dash area when the climate control system is
in the defroster setting. The noise may be heard when the vehicle has soaked in cold or hot temperatures for a period of time and then the climate control
is set at opposing temperatures. This will cause a thermal expansion/contraction of the defroster ducts causing the popping noise.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
SOME POPPING SOUNDS FROM THE HEATER A/C DUCTS ARE NORMAL. THIS REPAIR PROCEDURE WILL NOT ELIMINATE ALL
POP NOISES BUT WILL SIGNIFICANTLY REDUCE THE FREQUENCY OF THE POPS.
NOTE
FOR FUSION AND MILAN VEHICLES FOLLOW STEPS 1-11. FOR ZEPHYR VEHICLES ONLY FOLLOW STEPS 6-11. ZEPHYR HAS A
DIFFERENT DEFROSTER DUCT DESIGN THAT DOES NOT HAVE SNAP TABS AND AS A RESULT IS NOT NECESSARY TO
PERFORM THE BONDING PORTION.
1.
Remove the passenger side air bag following Workshop Manual (WSM), Section 501-20B.