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http://us.f13.yahoofs.com/bc/43dafb42mc9a58637/bc/Fusion+TSB+PDF+Files/tsb06-21-12+(Dash+Pop+Noise).pdf?BCPqkZGBTyw5mxXA

Just in time for the winter season. The illustrations didn't show up but just take it to your local dealer.

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.



Remove the passenger side air bag following Workshop Manual (WSM), Section 501-20B.
Using a small hand held mirror look at the back side of the duct that can be seen through the passenger side air bag opening. Look for the five (5) snap tabs that are on the back side and make a mark on the front side using a marker so the location is known. (Figure 1)


Figure 1 - Article 06-21-12


Use Motorcraft Nitrile Technician Gloves and apply Motorcraft Plastic Bonding Adhesive to the back side of each of the snap tabs with the index finger.
NOTE: ROTUNDA PART NUMBER 501-040 APPLICATOR GUN SHOULD BE USED TO DISPENSE THE PLASTIC BONDING ADHESIVE.



Apply a bead of plastic bonding adhesive to the edge of the duct opposite to the snap tabs (facing towards the glove box). The intent is to bond the front and rear sections of the defrost duct. (Figure 2) Allow plastic bonding adhesive to cure for 90 minutes before vehicle is returned to the customer.


Figure 2 - Article 06-21-12


Reinstall air bag following WSM, Section 501-20B.
Remove the defroster grille cover following WSM, Section 417-01. Be sure to disconnect the electrical connection to the light sensor (if equipped).
NOTE: IT IS NOT NECESSARY TO REMOVE THE LIGHT SENSOR FROM THE DEFROSTER GRILLE.



Use Instrument Panel to Duct Spacer and cut pieces to the following lengths:
Vane number 1 = 4 5/16" (110 mm) in length.
Vane number 2 = 2 3/4" (70 mm) in length.
Vane number 3 = 2 9/16" (65 mm) in length.
Vane number 4 = 2 3/16" (55 mm) in length.
Vane number 5 = 2 3/4" (70 mm) in length.
Use Figure 3 to match up spacer to correct vane locations.


Figure 3 - Article 06-21-12


Lubricate each center groove of the five spacers using Motorcraft electrical grease to aid in installation.
Using needle nose pliers, slide each spacer in the appropriate vane far enough that the defroster grill can be installed without interference.
NOTE: IF A SPACER WILL NOT GO IN ALL THE WAY, MARK IT WITH A FELT MARKER, REMOVE IT AND CUT SO THAT IT WILL BE SHORT ENOUGH TO CLEAR THE DEFROSTER GRILLE ONCE IT IS REINSTALLED. BE VERY CAREFUL WHEN INSTALLING SPACERS NOT TO DROP THEM IN THE DUCT. IF ONE IS DROPPED INSIDE, THE COMPLETE INSTRUMENT PANEL WILL HAVE TO BE REMOVED TO GET IT OUT.



Once all spacers are in place reinstall the defroster grille following WSM, Section 417-01.
 

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its getting rather chilly here in wisconsin last few days, and meh dash is popping! lol.. not a big issue, iam not a very picky person.  maybe someday if iam bored i will take it in.

and still no recalls eh? thats pretty impressive imho.
 

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I can't believe it took the dumb asses at Fud a YEAR to figure this out. I called them to complain about a few days after I got my car!
 

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NOTE: SOME POPPING SOUNDS FROM THE HEATER A/C DUCTS ARE NORMAL :rofl: Now thats a feature most won't appreciate.
 

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[quote author=MKII link=topic=59501.msg1018743#msg1018743 date=1161217577]
NOTE: SOME POPPING SOUNDS FROM THE HEATER A/C DUCTS ARE NORMAL :rofl: Now thats a feature most won't appreciate.
[/quote]

So people are supposed to spend ~$23k on a car that has "normal" popping sounds from the AC? No car I've owned previously had any "normal" popping sounds....I don't recal ANY of them having ANY popping sounds. Why not just come clean and say "We've loaded cars up with so much shitty cheap plastic so our interiors sound like an 80yr old arthritic knee."
 

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[quote author=Showtime link=topic=59501.msg1020727#msg1020727 date=1161304396]
"...interiors sound like an 80yr old arthritic knee."
[/quote]

Maybe more like a 20 year old replacement knee?
 

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I got this done a couple of weeks ago. When I picked it up, the service guy says "you know this won't cure all the noise, but 80% of it should go away". I don't know what they did, but now I have twice the noises from the dash. Also, it looks like the defroster grill (or whatever you call the thing on top) isn't sitting flush with the dash. It sort of bows up in the middle. I am very OCD and things like these noises drive me crazy. I'm going to have to take it back and see if they can fix it, but I was curious if anyone else had this TSB done and noticed an improvement. Thanks
 

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[quote author=canyon85 link=topic=59501.msg1007661#msg1007661 date=1160690013]
LOL....Yeah, like I'm gonna trust them to do this right. Just turn the radio up till the car warms up....
[/quote]
+1

I'm with you. No way do I want anyone disassembling the dash to fix a sound that will disappear once the car warms up. Apparently this only applies to 2006 models. I guess something got re-engineered? Boz
 

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[quote author=ming321 link=topic=59501.msg1180874#msg1180874 date=1170351597]
Unfortunately my noises continue even after the car is heated up. It was that way before the "fix", and still that way afterwards. It also did it in the warmer months.
[/quote]
That's a bummer. Boz
 
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