Thread: Design flaw in Air Compressor (Noise) LR3, LR4 and RRs

Design flaw in the air compressor mounting system (LR3-LR4-RRs, not sure about the RR).

Air Compressor noises, maybe a $0.22 fix.

Over the last year or 2 I have had the Dealership fix a noisy air compressor several times; each time was under warranty so no real big deal. The Air Compressor was making a lot of noise, but the computer was showing nothing wrong and everything on the suspension was working fine, so I would deal with the noise until my next oil change and the dealer would replace the entire compressor, they would chalk it up to warranty.

After each “fix” by the dealer, it would be good for a few months or so then start up again. After the warranty went out, they quoted me $1,100 to fix it again. This time I decided to actually find a solution. I expected to have to manufacture my own mounting bracket and raise it up and out of the way of the off-roading obstacles even considered moving the air compressor and the entire system, thinking that would keep it from happening again once I put a new air compressor on. (which by the way a new replacement air compressor is $150 at the ford dealer, just tell them you have a Eddie Bauer Expedition)

Turns out that the problem was a “Black Fender Washer” that is at the main bolting point of the Air Compressor and the Mounting Bracket. This washer is designed to set recessed into the mounting bracket. The washer is also designed to be a very tight fit. The problem is that after time the washer vibrates over to one side and rubs and knocks up against the mounting bracket, causing a lot of noise.

The dealership’s term for this is: “Your off-roading has knocked the compressor’s exhaust silencer loose, causing damage to the compressor”.

No, the off-roading would just speedup the process of that washer shifting it's location. So I took the washer up to ACE Hardware and got a new one, the new one has an outside diameter 1/8” smaller. The new washer gives it room to slide around over time without coming into contact with the mounting bracket.

For 22 cents, my $1,100 problem is all fixed.

To test this, I loosened the factory washer, placed a flat head screw driver between it and the mounting bracket and re-tightened, the noise was gone. Then I took the screwdriver and slide the washer over a hair, the noise was back. Once I got the new washer on the noise went away again. This time giving me more room for the washer to vibrate without coming into contact with the mounting system.

Love it!

now package it and sell it for a low low price of $9.99. but wait, there is more. Buy 1 new fender washer and get another one free!

You're so sophisticated, if it were my offroad vehicle the "clearance tolerance" would have been modified with a blunt chunk of iron.

Is the Ford Compressor exactly the same? Mounts are the same?

Model or Part Number?

The Ford compressor does not have a "heat sensor" wire. which I do not use. Also you can use one of the mounting holes, but you will have to make your own adapter, which took me about 5 minutes.