Suspension - Front Suspension Clacking/Clunking Noises
40 08 012016342/2
May 28, 2008
Supersedes Technical Service Bulletin Group 40 number 07-01 dated
October 22, 2007 to correct an error in the header data.
Vehicle Information
Clacking noise from front upper suspension or bushings torn (D3)
Condition
^ Clacking or clunking noise coming from front suspension area.
^ No vehicle stability issues are associated with this concern.
Technical Background
The front upper link(s) bushing is worn or torn.
Production Solution
Not applicable.
Service
Inspect Front Upper Link Suspension
Visually inspect the front suspension upper link rubber bushing (Figure 1, 1) and the rubber boot on the outer ball joint (Figure 1, 2) on all four upper links for cracks or wear.
Wear may entail:
^ The rubber is clearly cracked, as in Figure 2.
^ The bushing insert is displaced due to a complete rip in the bushing, as shown in Figures 3 and 4.
^ At any stage of deterioration, the link is always captured and will not result in reduced vehicle stability.
^ The bushing insert has a hairline crack in the surface, as shown between the green lines in Figure 5.
A hairline crack in the surface (as shown in Figure 5) does not require the bushing to be replaced.
If the rubber is clearly cracked (as shown in Figure 2) or the bushing insert is displaced (as shown in Figures 3 and 4):
^ And if there is damage to the outer ball joints (Figure 1, 2), replace all four upper links as per the ElsaWeb Repair Manual by ordering upper link part set 4E0 498 998.
^ And if there is no damage to the outer ball joints (Figure 1, 2) replace all four rubber bushings (Figure 1, 1) on all upper links as per the Upper Link Bushing Replacement instructions below.
Upper Link Bushing Replacement
1. Remove front and rear links on both sides from the vehicle as described in the ElsaWeb Repair Manual, under 40 Front suspension >> Upper link, removing and installing. Follow proper predecessor repair procedure.
Note:
Carefully remove the link ball joint from the wheel bearing housing.
Avoid
damaging the linkage stubs so the links may be reused. If the stub is damaged during removal, replace the entire linkage set as stated above.
2. Once the links are removed from the vehicle, hold the link in a vice with protective jaw covers. Assemble the 3348 and 3301 tools as shown in Figure 6.
Tighten the nut until the bushing is pressed out.
3. Place and align the new bushing in the link as shown in Figure 7 with the cutouts (see arrows) placed and aligned in the link according to Angle A. This angle must be 90° +/- 1°.
Note:
Improper alignment of the bushing may cause premature wear and failure of this bushing.
4. Press the bushing into place. Assemble the 3348 and 3301 tools as shown in Figure 8.
Tighten the nut until the bushing is pressed into place.
5. Reinstall the front and rear links on both sides from the vehicle as described in the ElsaWeb Repair Manual.
Warranty
When procedure applies to vehicles under warranty, use the following:
SAGA
Required Parts and Tools
Additional Information
All parts and service references provided in this TSB are subject to change and/or removal. Always check with your Parts Department and service manuals for the latest information.