Suspension - Front/Rear Knocking Noise On Bumps
No: LTB00167Issue: 2
Date: 09 NOV 2009
ISSUE '2' CHANGES ARE HIGHLIGHTED WITH GRAY BACKGROUND AND/OR ASTERISKS.
SECTION: 204
Stabilizer Bar Bushing Knock Noise
AFFECTED VEHICLE RANGE
CONDITION SUMMARY:
Situation:
While driving, a knock noise may be heard from the front or rear suspension. This may be caused by pre-compression in the stabilizer bar bushing or, with wear, paint removal causing free-play.
*NOTE:
Stabilizer bar packers must be installed to the front and rear stabilizer bars as a 'set' and only if the stabilizer bar bushings are serviceable. If the stabilizer bar bushings are not serviceable, refer to Microcat for the correct, updated stabilizer bar bushing. If fitting new, updated stabilizer bar bushings, do not install stabilizer bar packers.*
Action:
In the event of a customer concern of the above *and if the stabilizer bar bushings are serviceable* refer to the Repair Procedure outlined below to install front and rear stabilizer bar packers.
PARTS
TOOLS:
Refer to Workshop Manual (GTR) for any special tools required
WARRANTY:
NOTE:
Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only. Always refer to DDW to obtain the latest repair time.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
REPAIR PROCEDURE
INSTALL REAR STABILIZER BAR BUSHING PACKERS
NOTE:
Global Technical Reference (GTR) lookup sequence is as follows: GTR Home > NAS > Model > Service Information > Model Year > Workshop Manuals
1. *Inspect the rear stabilizer bar bushings for:
^ Free play by attempting to move the stabilizer bar within the bushing by hand.
^ Cracks or splits
^ 'Old' or ' New ' style ('A' or 'B', Figure 1)
2. If any free play, cracks, or splits are found in the stabilizer bar bushings, refer to Workshop Manual (GTR) Section 204-02 to replace the rear stabilizer bar bushings; do not install stabilizer bar packers. To be carried out as a separate claim.
3. If 'New' style stabilizer bar bushings are fitted, do not install stabilizer bar packers. Diagnose as a separate claim.
4. If no free play, cracks, or splits are found in the stabilizer bar bushings, refer to Workshop Manual (GTR) Section 100-02 to raise and support the vehicle.*
5. Loosen (do not remove) the two nuts on left and right-hand rear stabilizer bar bushing brackets.
6. Reposition stabilizer bar bushing / brackets to allow sufficient clearance between bushing and chassis. (Figure 2)
7. Install bushing packer between left and right-hand bushing and chassis. (Figure 2)
CAUTION:
Ensure the bushing packer is not trapped between the stabilizer bar bushing bracket and chassis.
8. Tighten the two nuts on the left and right-hand stabilizer bar bushing brackets to 62 Nm (46 lbf ft).
INSTALL FRONT STABILIZER BAR BUSHING PACKERS
NOTE:
Global Technical Reference (GTR) lookup sequence is as follows: GTR Home > NAS > Model > Service Information > Model Year > Workshop Manuals
1. *Inspect the front stabilizer bar bushings for:
^ Free play by attempting to move the stabilizer bar within the bushing by hand.
^ Cracks or splits
^ 'Old' or 'New' style ('A' or 'B', Figure 1)
2. If any free play, cracks, or splits are found in the stabilizer bar bushings, refer to Workshop Manual (GTR) Section 204-02 to replace the front stabilizer bar bushings; do not install stabilizer bar packers. To be carried out as a separate claim.
3. If 'New' style stabilizer bar bushings are fitted, do not install stabilizer bar packers. Diagnose as a separate claim.
4. If no free play, cracks, or splits are found in the stabilizer bar bushings, refer to Workshop Manual (GTR) Section 100-02 to raise and support the vehicle.*
5. Loosen (do not remove) the two nuts on left and right-hand front stabilizer bar bushing brackets.
6. Reposition stabilizer bar bushing / brackets to allow sufficient clearance between bushing and chassis. (Figure 3)
7. Install bushing packer between left and right-hand bushing and chassis. (Figure 3)
CAUTION:
Ensure the bushing packer is not trapped between the stabilizer bar bushing bracket and chassis.
8. Tighten the two nuts on the left and right-hand stabilizer bar bushing brackets to 115 Nm (85 lbf ft).
9. Lower vehicle.