Suspension - Pop/Clunk Noise Under Floor

Classification:
FA00-008a

Reference:
NTB00-075a

Date:
December 14, 2000

"POP" OR "CLUNK" NOISE UNDER FLOOR

This bulletin amends NTB00-075 and includes clarified Applied Model Information. Please discard all paper copies of NTB00-075.

APPLIED VEHICLE(S):
1999 Frontier (D22) 4WD
2000 Frontier (D22) V6 "Desert Runner"
2000 Frontier (D22) King Cab 4WD and Crew Cab 4WD
2000 Xterra (WD22) 2WD and 4WD

SERVICE INFORMATION





Use the service procedure detailed below if one of the Applied Vehicles makes a "pop" or "clunk" noise beneath the floorboard which appears to be coming from behind the front seats, particularly at low speeds while accelerating or when coming to a stop. Such a noise may be caused by movement of the anchor arm at the # 2 crossmember. If so, it may be resolved by the addition of a spacer washer in the location shown in Figure 1.

SERVICE PROCEDURE

1. Road test vehicle to duplicate and confirm the noise.

2. If the noise is confirmed, raise the vehicle on a hoist. Make sure all load is off the suspension.





3. Move torsion bar dust cover forward.





4. Paint matching marks on torsion bar spring and corresponding arms.

CAUTION:
Use paint to place the matching marks. Do not scribe the affected parts.





5. Measure anchor bolt protrusion "L" and remove the lock nut and adjust nut.





6. Remove torsion bar spring as follows: Remove torque arm fixing nuts, then withdraw torsion bar spring forward with torque arm.

7. Remove torsion bar anchor arm from frame at # 2 crossmember.





8. Install spacer washer, P/N 01311-0003U, over the front of the anchor arm, between the # 2 crossmember and the anchor arm (see Figure 6).

9. Apply chassis grease to the splines on both ends of the torsion bars. Reassemble anchor arm and torsion bar into vehicle, making sure of all alignment marks. Tighten torque arm fixing nuts to 65-88 ft. lb.

10. Adjust anchor bolt nuts back to original "L" protrusion measurement (see Figure 4).

11. Replace dust cover.

12. Road test to assure the "pop" noise is eliminated.

13. Use service manual procedure to make a final check on vehicle posture (ride height). Adjust as necessary.





PARTS INFORMATION

CLAIMS INFORMATION





Submit a Primary Failed Part (PP) line claim using the claims coding shown.