Suspension - Front End Thumping Noise on Bumps
Date: March 28, 2007Order No.: P-B-32.25/07a
Supersedes: P-B-32.25/07 dated September 2001
Group: 32
Revision History
Revision Date Purpose
a 3/28/07 Repair Procedure Revised
- 9/01 Initial issue
SUBJECT:
Model 203.040/061/064/065/081/084/261/264/740/747/764
Up to VIN A072600, F097000 and R017000
Thumping Noise from Front Axle Area While Driving Over Bumpy Road
If you receive customer reports in the above model vehicles of a thumping noise occurring from the front axle area while driving over bumpy roads, it is possible that the clearance between the rebound stop (Figure 1, B) and the rubber ring on the top of the front damper strut is too small.
Note:
Experience has shown that the front damper strut is not involved in producing this type of noise.
Note:
In determining whether the above condition is the cause of the thumping noise and appropriate repair steps, please check VMI to determine if vehicle has been previously repaired prior to beginning the repair procedure below. Also updated rebound stops which have been incorporated into production are temporarily marked with yellow paint dots.
Repair Procedure
1. Verify that vehicle is within VIN range.
2. Check for modified rebound stops with yellow paint dots.
Note:
If a new/modified rebound stop has been installed, please proceed to Step 8 below.
3. Test drive vehicle to determine/verify noise in area of front axle.
4. Measure clearance between the rebound stop (Figure 2, B) and the Rubber ring. If the clearance is below 1 mm, then the rebound stop (Figure 2, B) must be replaced.
5. Remove the 21 mm nut which secures the rebound stop to the damper strut assembly.
Note:
It is not necessary to remove the damper strut assembly.
6. Replace the removed rebound stop with a new rebound stop.
7. Secure the new rebound stop with a new 21 mm nut. Refer to WIS document AR32.25-P-1018P for the torque value for the newly installed 21 mm nut.
8. If the noise continues even with the new/modified rebound stop installed, the rubber mounts of the front anti-roll bar must be checked.
9. Unhook the drop link leading to the front axle's anti-roll bar. Refer to WIS document AR32.20-P-0300P.
10. Check for free play within the anti-roll bar rubber mounts by moving the anti-roll bar back and forth. If there is any play noticed while checking the anti-roll bar rubber mounts for free play, the anti-roll bar rubber mounts must be replaced. Refer to WIS document: AR32.20-P-0300P.
Parts Information
Note:
The following allowable labor operations should be used when submitting a warranty claim for this repair.
In Case of Warranty, use the table.