Escape 2WD L4-2.5L (2009)
Muffler: All Technical Service Bulletins
Exhaust System - Metallic Noise On Cold Start Up
TSB 10-3-5
03/01/10
2.5L - 10-20 SECOND EXHAUST NOISE AFTER OVER
NIGHT SOAK (EXCLUDES HYBRID)
FORD:
2009 Escape
MERCURY:
2009 Mariner
This article supersedes TSB 09-25-1 to remove the production build date.
ISSUE
Some 2009 Escape and Mariner vehicles equipped with 2.5L engine (excludes Hybrid) may exhibit a metallic exhaust noise during first 10-20 seconds of
operation during a cold start (engine off for 2 or more hours). The noise decreases as the exhaust system warms up.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Is exhaust noise only audible during first 10-20 seconds of operation during a cold start (engine off for 2 or more hours)?
a. Yes - Proceed to Step 2.
b. No - Stop as procedure does not apply.
Follow normal Noise, Vibration and Harshness (NVH) diagnostics per Workshop Manual (WSM), Section 100-04.
2. With the vehicle in neutral, position it on a hoist. Refer to WSM, Section 100-02.
NOTE
POSITION HOIST LIFT ARM CLEAR OF EXHAUST HEAT SHIELD.
3. With the exhaust system installed on vehicle, measure 3" (75 mm) from the end of the catalytic converter outlet weld and mark the pipe. Install hose
clamps to either side of mark. Using reciprocating saw, cut pipe between the clamps using clamps as a guide. (Figure 1)
4. Remove and discard the muffler portion of the catalytic converter and muffler assembly.
5. De-burr the cut edge of the catalytic converter outlet pipe. Using sandpaper or equivalent, clean the rust from the outside surface of the outlet pipe.
6. Remove and discard the underbody heat shield. If equipped, cut off the body stud for the old heat shield. Replace with new heat shield listed in parts
list. Reuse original heat shield fasteners and torque to 3 lb-ft (4 N.m).
