Body/Frame - Rear Floor Popping/Creaking Noise

Classification:
BT03-047

Reference:
ITB04-002

Date:
January 7, 2004

2003 FX; CREAK AND/OR POP NOISE FROM REAR FLOOR AREA

APPLIED VEHICLE:
2003 FX35/FX45 (S50)

APPLIED VIN(S):
Built before
JNRAS08U(*)3X 102879,
JNRAS08W(*)3X 206541, or
JNRBS08W(*)3X 403940

APPLIED DATE:
Built before May 28, 2003

IF YOU CONFIRM:
A creaking and/or popping noise is heard coming from the rear floor area (cargo area) while driving
^ Over bumps (speed bumps, potholes, dips, etc), and/or
^ In and out of driveways,

NOTE:
This noise may sound like it is coming from the rear suspension.

ACTIONS:
^ Confirm the noise is coming from the rear floor "gusset(s)" (support members).
^ Replace the bolts holding the rear floor gussets.





PARTS INFORMATION

CLAIMS INFORMATION





Submit a Primary Failed Part (PP) line claim using the claims coding shown.

IMPORTANT:
The purpose of "ACTIONS" (above) is to give you a quick idea of the work you will be performing. You MUST closely follow the entire Service Procedure as it contains information that is essential to successfully completing this repair.

SERVICE PROCEDURE

1. Use Chassis Ears J-39570 (or equivalent) to confirm noise is coming from floor gusset(s).

a. Fold down the rear seat back.








b. Lift the Luggage Floor Cover-right or left side (item # 5 or 6 in Figure 1). With the floor cover lifted you will be able to see the floor gusset.





c. Attach the Chassis Ear Sensor to the floor gusset (see Figure 2).

d. Drive the vehicle to duplicate the noise.

2. Remove all of the items shown in Figure 1.
^ Refer to section EI of the Service Manual (ESM) for clip and fastener information.

3. Remove the floor brace shown in Figure 2
^ This brace will be visible after all of the luggage area trim is removed.

^ There are 11 bolts holding this brace.





4. Replace the 12 bolts holding the floor gussets (6 on each side).

^ Use the new bolts (see Parts Information).

^ The floor gusset bolts are 6 mm bolts with a 10 mm drive head.

^ Tighten the bolts to 64 - 95 in-lb/5.3 - 8.0 ft-lb (0.73 - 1.1 kg-m, 7.2-10.8 N-m)

NOTE:
^ This is a new bolt and torque specification for this application.
^ Do not use the torque specification from the Service Manual (ESM).

5. Re-assemble in reverse order.