Suspension - Front Suspension Popping/Clunking Noise
Suspension02-003/04
2003-2004 MAZDA6 - POPPING / CLUNKING
NOISE FROM FRONT SUSPENSION
APPLICABLE MODEL(S)/VINS
2003 - 2004 Mazda6 vehicles built before Feb. 1, 2004.
DESCRIPTION
While the vehicle is moving or stopped, a popping/clunking noise can be heard from the front suspension when turning the steering wheel in either direction. The noise continues throughout the steering wheel travel.
Customers having this concern should have their vehicle inspected and repaired using the following repair procedure.
REPAIR PROCEDURE
1. Verify customer concern.
2. Remove the front shock absorber and coil spring assembly according the Workshop Manual (Section 02-13) FRONT SHOCK ABSORBER AND SPRING REMOVAL/INSTALLATION.
WARNING:
The coil spring is under pressure and will require the use of a coil spring compressor. Make sure to wear safety goggles and follow all safety precautions according to the instructions for the coil spring compressor being used.
3. Disassembly the coil spring assembly.
4. Remove and discard the original (brown) coil spring insulator from the bottom of the spring.
5. Using brake cleaner and a shop rag, completely clean all oil and grease from the following areas:
WARNING:
Always wear safety goggles and protective gloves when using brake cleaner.
^ Clean the top and bottom two (2) coils of the coil spring.
^ Clean the bottom of the strut seat.
^ Clean the upper rubber spring seat.
6. Install the (large) coil spring insulator onto the bottom of the coil spring.
NOTE:
Be sure to leave 1/8" of insulation beyond the end of the coil.
7. Install the (small) coil spring insulator onto the second coil extending 1" beyond the end of the top coil.
8. Reassemble the front shock absorber and coil spring assembly according the Workshop Manual (Section 02-13) FRONT SHOCK ABSORBER AND SPRING REMOVAL/INSTALLATION.
NOTE:
Do not use any grease or lubrication on the new rubber insulators, rubber spring seat, or any portion of the coil spring assembly.
9. Repeat Steps 2 - 8 on the other side front coil spring assembly.
10. Verily repair.
PART(S) INFORMATION
NOTE:
Order two (2) of each insulator part listed above to repair one (1) vehicle.
WARRANTY INFORMATION
NOTE:
^ This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair. Refer to the SRT microfiche for warranty term information.
^ Additional diagnostic time cannot be claimed for this repair.