Drivetrain - Front Axle Knocking Noises in Extreme Cold

Bulletin No.: 03-004/08

Last Issued: 04/11/2008

Subject:
KNOCKING NOISE FROM DRIVESHAFT WHEN TURNING IN EXTREME COLD TEMPERATURES

APPLICABLE MODEL(S)/VINs
2006-2007 Mazdaspeed6

2003-2007 Mazda6 vehicles produced before Oct. 1, 2007

2007-2008 CX-7 vehicles with VINs lower than JM3ER******188196
(produced before Oct. 1, 2007)

2007-2008 CX-9 vehicles with VINs lower than JM3TB******134353
(produced before Sept. 17, 2007)

DESCRIPTION

At extremely cold ambient temperatures of -15°C (5°F), some vehicles may exhibit a knocking noise from the front drive shafts when the vehicle is moving with the steering wheel turned fully right or left. The noise disappears after a couple of minutes of driving.The grease in the outer (wheel side) joint of the front drive shaft becomes harder in extreme cold temperatures and stick-slip occurs in the joint.

The outer joint grease has been modified at mass-production to eliminate the noise.

Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

1. Verify customer concern.





2. Remove front drive shafts according to Workshop Manual (section 03-13 FRONT DRIVE SHAFT REMOVAL/INSTALLATION).





3. Disassemble drive shafts according to Workshop Manual (section 03-13 FRONT DRIVE SHAFT DISASSEMBLY/ASSEMBLY).

4. Wipe off old grease in outer (wheel side) joint and clean it with brake cleaner.

NOTE:
The outer (wheel side) joint cannot be disassembled, however, it can be accessed through the joint.

5. Assemble drive shafts according to Workshop Manual (section 03-13 FRONT DRIVE SHAFT DISASSEMBLY/ASSEMBLY).

6. Fill new boot (wheel side) with modified grease according to Workshop Manual (ex. CX-7 grease amount: 110-130 g {3.89-4.58 oz.}).

NOTE:
The new boot set includes modified grease (NGK509) for outer (wheel side) joint.

7. Reinstall front drive shafts according to Workshop Manual (section 03-13 FRONT DRIVE SHAFT REMOVAL/INSTALLATION).

8. Verify repair.





PART(S) INFORMATION





WARRANTY INFORMATION





Disclaimer