Procedure
NOTE:Refer to sections 32 and 33 of the appropriate service manual for component disassembly and reassembly instructions.
1. Verify the conditions when the noise occurs with the customer. Then test drive the vehicle to duplicate the noise. If the exact location of the noise cannot be determined, first check all suspension parts for abnormal wear, damaged parts and tightening torque.
a. Replace any damaged or worn parts.
b. Tighten any loose parts to the torque specified in the service manual.
c. If no parts damage, abnormal wear, or looseness is evident, go to Step 2.
2. Crossmember Attachment Inspection
a. Using a hoist, lift the vehicle enough to remove all spring tension from ("unload") the suspension.
b. Locate the crossmember mounting points (one bolt and two nuts per side).
c. Check the mounting bolts and nuts for proper tightening torque.
Bolt torque specification: 108 Nm (78 ft-lbs)
Nut torque specification: 88 Nm (64 ft-lbs)
If a bolt or nut is loose, check to see if the threads are stripped. Replace if necessary.
d. Check attaching bolts and nuts for the brackets, roll stoppers, and brackets for looseness. Tighten as required.
e. Test drive the vehicle. If the abnormal front suspension noise still exists, continue with Step 3.
3. Stabilizer Bar Inspection
a. Position the vehicle on an alignment rack or over a pit. The vehicle weight must be on all wheels for this inspection.
b. Shake the stabilizer bar to determine whether there is any looseness ("play") between the bar and the bushings.
(1) If there is play between the stabilizer bar and the bushings, replace the bushings using parts listed in the PARTS INFORMATION section of this bulletin. Then test drive the vehicle. If the abnormal front suspension noise still exists, continue with Step c.
(2) If there is no play between the stabilizer bar and the bushings, continue with Step c.
c. Check the breakaway torque of the stabilizer link ball joints. Torque specification: 1.5 Nm (13 in-lbs)
^ If the breakaway torque is over the specification, replace the stabilizer link.
^ If the breakaway torque is lower than the specification and the excessive axial play is less than 0.1 mm, do not replace the stabilizer link.
d. Inspect the stabilizer link and dust cover for damage.
Replace the stabilizer link if damaged. If only the dust cover is damaged, replace only the dust cover.
e. Test drive the vehicle. If the abnormal front suspension noise still exists, continue with Step 4.
4. Lower Lateral Arm Inspection
a. Using a hoist, lift the vehicle enough to remove all spring tension from ("unload") the suspension.
b. Check the free play of the lateral arm ball joints on both sides as follows:
(1) Keep the wheels in a straight direction.
(2) Remove the front wheels.
(3) Securely fasten the brake rotors by installing the lug nuts.
(4) Affix a magnetic base dial indicator to the rotor. Place the dial indicator in a vertical position contacting the bottom center of the lower lateral arm ball joint.
(5) Move the brake rotor and lower compression arm vertically several times by hand. Read the free play (amount of movement) on the dial indicator
(6) If the free play is over 0.5 mm, replace the lower lateral arm, using the new, improved part listed in the PARTS INFORMATION section of this bulletin.
NOTE:
Substitute the free play measurement taken in Step (5) for the breakaway torque specification.
(7) Verify that there is no damage to the dust cover. If the dust cover is damaged, replace only the dust cover.
(8) Test drive the vehicle. If the abnormal front suspension noise still exists, continue with Step 5.
5. Upper Arm Inspection
a. Using a hoist, lift the vehicle enough to remove all spring tension from ("unload") the suspension.
b. Check the tightening torque of the upper arm shaft bolts. If out of specification, tighten to the specified torque.
Torque specification: 57 Nm (41 ft-lbs)
c. Test drive the vehicle.
(1) If the abnormal front suspension noise still exists, continue with Step d.
(2) On 1996 Galants only. a knocking noise when driving on rough roads may be caused by the upper arm contacting the inner fender well. Repair as follows:
^ Inspect the upper arm for any sign of interference with the inner fender well at the area shown.
^ Using a mallet, slightly modify the area of the inner fender well where it interferes with the upper arm. Only 3 - 5 mm (1/8 - 3/16 in.) modification should be needed. If extensive damage (such as bending) to the upper arm or upper arm ball joint occurs, replace the upper arm assembly with the new, improved part listed in the PARTS INFORMATION section of this bulletin.
d. Check the upper arm ball joint breakaway torque as follows:
(1) Shake the ball joint stud several times.
(2) Install the nut to the stud.
(3) Use special tool MB990326 preload socket to measure the ball joint breakaway torque.
Torque specification: 0.3 - 1.5 Nm (3-13 in-lbs)
e. If the breakaway torque is out of the specified range, replace the upper arm assembly. The new upper arm assembly has sealer on the top of the ball joint to protect against water intrusion.
f. Verify that there is no damage to the dust cover. If the dust cover is damaged, replace only the dust cover.
g. Test drive the vehicle. If the abnormal front suspension noise still exists, continue with Step 6.
6. Lower Compression Arm Inspection
a. Using a hoist, lift the vehicle enough to remove all spring tension from ("unload") the suspension.
b. Check the lower compression arm ball joint breakaway torque as follows:
(1) Shake the ball joint stud several times.
(2) Use special tool MB990326 preload socket to measure the ball joint breakaway torque.
Torque specification: 0.5 - 2.5 Nm (4-22 in-lbs)
c. If the ball joint breakaway torque is out of the specified range, replace the lower compression arm assembly.