Body - Front End Pop/Click/Creak Noises on Bumps

Classification:
BT04-034a

Reference:
ITB04-043A

Date:
February 22, 2005

2003-2004 FX; POP, CLICK, OR CREAK NOISE FROM FRONT FENDER AREA

This bulletin amends ITB04-043. The Service Procedure and Claims Information have been amended to include removal of the front fender(s). Please discard all paper copies of the earlier version.

APPLIED VEHICLES:
2003-2004 FX45 (S50) AWD
2003-2004 FX35 (S50) 2WD and AWD

IF YOU CONFIRM:

A metal to metal noise-pop, click, creak, etc-coming from the left and/or right front of the vehicle.

NOTE:
This noise, if it occurs, may be heard while driving at low speeds (under 20 mph) and when:

^ Entering/exiting a driveway, or

^ Driving over bumps (like a speed bump).

ACTIONS:

1. Use Chassis Ears to determine which side the noise is coming from.

2. Replace the body bolts (see Service Procedure) on the side the noise occurs.

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.





PARTS INFORMATION

CLAIMS INFORMATION





Submit a primary Failed Part (PP) line claim using the claims coding table.

SERVICE PROCEDURE

1. Use essential tool J-39570 (Chassis Ear Electronic Listening Tool) or equivalent to determine if the noise is coming from the left or right front fender area.

^ Chassis Ear Electronic Listening Tool (J-39570 an essential tool) is available from TECH-MATE.

2. On the side the noise is coming from, remove the front fender.

^ See the BL section of the appropriate Service Manual (ESM) for fender removal information.





3. Replace the M6 bolts shown in Figure 1.

^ Use the new bolts listed in the Parts Information.

^ Tighten the bolts to:
8.5 Nm (0.86 kg-m 75 in-lb).

4. Reinstall all parts removed.

5. Test drive the vehicle to make sure the noise is gone.





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