Quote:
Originally Posted by northern piper
What else is there? Motor mounts? I did have the recall done on the sub frame...
any thoughts?
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Check CV joints and main subframe bushings (aka "donuts") at the bottom, Even if Ford replaced the subframe it doesn't mean they put in new main bushings. If you still have the originals they are probably rock-hard by now. This makes a major difference in ride quality and body rattle levels. The donuts are usually replaced along with motor/tranny mounts because it is part of the same process (see below). If you don't want to tackle this you should at least make sure the main subframe link bolts are tight, loose subframe bolts make steering mushy and "weavy", the car sways when turning.
Motor and transmission mounts should be checked as well, if they are worn the engine shakes and rattles on rough surfaces and you can feel this in the steering wheel. This cannot be too good for the engine.
Replacing the mounts is definitely not an easy job, in fact it's 44-step process. That's right, forty-four. On top of regular tools and jacks it requires the use of an engine support brace, 2 engine lifting brackets (these are used to hang the engine to the support brace) and a plateau-type transmission jack/lift is required in order to lower the subframe once the link bolts are removed, to gain access to the engine and transmission mounts. For the backyard mechanic this is easily a 10-hour ordeal, but most shops will do it in two.
Another option is to take the van to a DIY shop to do the job yourself but with access to proper equipment and lifts, it could be done in about 3 hours. The latter is my favorite because you have full control over what is done and can inspect your vehicle closely while you're at it, of fix stuff you keep postponing doing at home on account of limited equipment.
The above is the reason why older cars always seem to rattle a lot more than new cars and handle poorly on rough roads even with all-new suspension parts installed. Most people simply do not know about bushings and engine mounts being a factor in ride quality and noise levels. It's like tires. Many drivers will complain their vehicle has acquired a harsh ride not knowing that driving with balding tires means progressively less cushioning between the road surface and the steel belting, which cause more vibrations to be transmitted to the wheel and from there, to the frame and occupants.