Front Suspension - Popping/Creaking Noises
NO: 02-02-97 Rev. AGROUP: Front Suspension
EFFECTIVE DATE: Dec. 15, 1997
SUBJECT:
Popping/Creaking Noise in Front Suspension
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-02-97 DATED FEBRUARY 28, 1997 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL FRONT SUSPENSION NOISE DIAGNOSTICS/REPAIRS HAVE BEEN ADDED. THE ADDITIONS ARE HIGHLIGHTED WITH ASTERISKS.
MODELS:
1995 - 1998 (PL) Neon
SYMPTOM/CONDITION:
**A popping noise from the front suspension may be experienced while:
^ Going in reverse or forward with the steering wheel turned completely in one direction (parking lot maneuvers).
^ Shifting from drive to reverse, reverse to drive, etc.
^ Pulling in/out of driveway.
^ Large dips/bumps in the road such as speed bumps. **
DIAGNOSIS:
If the customer describes the front suspension noise in conditions such as those described above, perform the Repair Procedure.
PARTS REQUIRED:
NOTE:
THE 1995 NEONS BUILT IN 1994 USED 13" KNUCKLE ASSEMBLIES WITH 13" OR 14" WHEELS. LATER BUILT VEHICLES HAVE 13" OR 14" KNUCKLE ASSEMBLIES TO MATCH ORIGINAL WHEEL SIZE. TO DETERMINE THE PROPER KNUCKLE SIZE, COUNT THE STUDS ON THE HUB THEN REFER TO THE PARTS LIST PROVIDED IN THIS BULLETIN.
CAUTION:
DO NOT USE THE WHEEL SIZE TO DETERMINE PROPER KNUCKLE PART NUMBERS.
REPAIR PROCEDURE:
**This bulletin involves inspecting/replacing as needed both front wheel bearings and steering knuckles, front upper strut mounts, engine mounts, and lubing the driveshafts.**
**NOTE:
USE TABLE TO DETERMINE WHICH STEPS TO PERFORM BASED ON VEHICLE BUILD DATE AND IF TECHNICAL SERVICE BULLETIN 02-02-97, DATED FEBRUARY 28, 1997 HAS BEEN PERFORMED.**
NOTE:
ALL FRONT KNUCKLE/BEARING/HUB REPAIR PROCEDURES FOR STEPS 1 THROUGH 5, CAN BE FOUND IN THE 1998 NEON SERVICE MANUAL (PUBLICATION NUMBER 81-270-8025) GROUP 2 (SUSPENSION).
1. Remove both left and right front knuckle/bearing/hub assemblies.
2. Press the hub out of the old knuckle/bearing/hub assemblies.
3. Press the old hubs into the new knuckle/bearing assemblies.
**4. Before the knuckle/bearing/hub assemblies are installed on the vehicle, put a small amount of grease (Wheel Bearing Lube - p/n 04318064) on the entire face of the driveshaft that makes contact with the hub bearing assembly (Figure 1).**
5. Install both left and right front knuckle/bearing/hub assemblies.
**6. Replace the upper strut mount by following the procedures in the 1998 Neon Service Manual (Publication No. 81-270-8025), Removal/Installation, pages 2-16 to 2-17, and Assembly/Disassembly procedures 1 thru 5 on pages 2-30 to 2-31 (Figure 2). The torque for the new upper strut mount nuts is 61 Nm (45 ft.lbs).**
**7. Remove and replace the right engine mount as outlined in the 1998 Neon Service Manual (Publication No. 81-270-8025) (SOHC - pg 9-18)(DOHC - pg 9-64). After replacing the right engine mount, squirt enough grease (Silicone Spray - p/n 04318070) between the mount snubber and the engine bracket to fill the gap (Figure 3).**
NOTE:
IF THE SILICONE SPRAY (P/N 04318070) IS NOT AVAILABLE, ANOTHER SILICONE SPRAY MAY BE USED. HOWEVER THE SUBSTITUTE SILICONE SPRAY MUST NOT BE PETROLEUM BASED.
**8. Inspect and tighten remaining suspension components to specification; repair or replace as needed.**
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
02-05-30-93 Knuckles and Mounts - Replace - All 2.9 Hrs.
02-05-39-91 Upper Strut Mounts and Engine Mount - Replace 1.3 Hrs.
09-40-21-91 Engine Mount Replace 0.3 Hrs.
FAILURE CODE: P8 - New Part