Suspension - Rear End Rattling Noise On Rough Roads

Bulletin No: 02-008/09

Last Issued: 08/19/2009

Subject
NOISE FROM REAR STABILIZER CONTROL LINK

BULLETIN NOTE
^ This bulletin supersedes the previous bulletin 02-008/09 issued on 08/17/09. The APPLICABLE MODEL(S)/ VINS and WARRANTY INFORMATION have been revised.

^ Changes are noted below in Red beside the change bar and/or shown in bold.

APPLICABLE MODEL(S)/VINS
2004-2009 Mazda3 (including Mazdaspeed3)

DESCRIPTION





Some vehicles may exhibit a rattle noise from the rear stabilizer control link when driving on a rough road. Due to excessive impact while driving, a lateral force is applied to the rear stabilizer control link ball joint that creates a gap, resulting in the rattle noise.

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

OUTLINE OF REPAIR

Install rubber bushing (A) and ring (B) at both rear stabilizer bushings (F= Front of vehicle). If any unusual noise, excessive clearance, damage on control link boot is found, replace the failed control link at the same time.

REPAIR PROCEDURE

1. Verify customer concern.





2. Without removal, inspect both sides of the control link for any unusual noise or excessive clearance. Check the control link boot (for cracks). If any problem is found on the control link, replace the damaged control link with a new one. Refer to MS3 online instructions or the Workshop Manual section 02-14 "Rear Stabilizer Removal/Installation."





3. Verify that both control link nuts are tightened properly.
Tightening torque: 43.1-60.8 Nm (31.8-44.8 ft-lbf)





4. Install the rubber bushing at the rear stabilizer bushing on both sides.

a. Cut off the protrusion (A) on the rear stabilizer bushing so that the rear stabilizer bushing makes flush contact with the rubber bushing.

NOTE:
There is no need to remove the bushing from the vehicle.





b. Install the rubber bushing (A) just next to the rear stabilizer bushing (B) as shown until they contact each other.





5. Install the clamp, facing the bolt head downward so that the bolt can be tightened from the rear side of the vehicle (R=Rear of vehicle).





6. Tighten the bolt until the marking, which is on the 8th or 9th ring slot, can be seen.





7. Verify repair (F=Front of vehicle).





PART(S) INFORMATION





WARRANTY INFORMATION

NOTE:
^ This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair.

^ This repair will be covered under Mazda's New Vehicle Limited Warranty term.

^ Additional diagnostic time cannot be claimed for this repair.