Suspension - Front End Popping/Clunking On Bumps
07-078March 2, 2012
Applies To:
See VEHICLES AFFECTED
Pop or Clunk From the Front Suspension While Driving Over a Bump After
Turning
(Supersedes 07-078, dated May 13, 2011,to revise the information marked by the black bars and asterisks)
REVISION SUMMARY
*Under WARRANTY CLAIM INFORMATION, some flat rate times were changed.*
SYMPTOM
There is a pop or clunk from the front suspension area when driving over bumps. This usually occurs after completing a tight (full lock) turn.
PROBABLE CAUSE
The front bump stops become dislodged and then pop back into place.
VEHICLES AFFECTED
CORRECTIVE ACTION
Replace both front bump stops, and glue them in place.
PARTS INFORMATION
Bump Stop (two required):
2-door and Si: P/N 51722-SVA-A04
4-door except S: P/N 51722-SNA-A03
Damper Pinch Bolts (four required):
P/N 90190-SNA-000
Flange Nut (10mm) (six required):
P/N 90304-S10-024
Self-locking Nut (two required):
PIN 90213-5J6-004
Self-locking Nuts (four required):
P/N 90213-5R3-013
REQUIRED MATERIALS
Adhesive: P/N 08712-0007
(one tube repairs about 10 vehicles)
WARRANTY CLAIM INFORMATION
The normal warranty applies.
Failed Part: P/N 51920-SVB-A03
Defect Code: 00504
Symptom Code: 04201
Skill Level: Repair Technician
DIAGNOSIS
1. Drive the vehicle in a few elongated figure-eight patterns. Hold the steering wheel at full lock in the turns with a short straight section between turns. Drive over a 2-inch dip or bump while going straight at 15mph.
^ If you hear a severe pop or clunk, go to step 2.
^ If you don't hear a pop or clunk after several attempts, this bulletin does not apply. Continue with normal troubleshooting.
2. Drive the vehicle in a straight line at 15 mph, alternating between forward and reverse (no turning) over the same bump as in step 1.
^ If you don't hear a pop or clunk, but you did in step 1, go to REPAIR PROCEDURE.
^ If you hear a pop or clunk, this bulletin does not apply. Continue with normal troubleshooting.
REPAIR PROCEDURE
1. Remove one front damper assembly:
^ Refer to page 18-29 of the 2OO~2O11 Civic Service Manual, Volume 2, or
^ Online, enter keyword DAMPER, and select Front Damper/Spring Removal and Installation from the list.
2. Disassemble the front damper assembly:
^ Refer to page 18-31 of the service manual, or
^ Online, enter keyword DAMPER, and select Front Damper/Spring Disassembly, Inspection, and Reassembly from the list.
3. Clean and dry the bump stop damper mounting base area.
4. Apply a continuous bead of adhesive to the damper mounting (base) cap area.
5. Install the new bump stop. Clean up any adhesive that may have squeezed out.
6. Reassemble the damper using a new self-locking nut. Torque the nut to 44 N.m (33 lb-ft).
7. Reinstall the damper assembly onto the vehicle using new pinch bolts and flange nuts. Torque the nuts to 90 N.m (67 lb-ft).
8. Repeat steps 1 thru 7 for the other front damper assembly.
9. Allow the vehicle to sit for 6 hours to allow the adhesive to dry.
10. Check the wheel alignment, and adjust it if needed.
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