Recall - Front Strut Reinforcement
TSB No. TS 03-01 03030Section Title: Steering/Susp.
Division: Automotive
Category: Technical
SUBJECT:
SAFETY RECALL CAMPAIGN: W2, FRONT STRUT REINFORCEMENT
MODEL:
SIDEKICK SPORT
YEAR:
1996-97
CONDITION:
Upper strut support mounting studs can break allowing the upper strut to come loose causing loss of control. Early initial indication may be a knocking noise from the front end strut area in turns or going over bumps.
CAUSE:
Front upper strut support mounting base is of insufficient strength.
CORRECTION:
Replace the front upper strut support and strut stay and install a reinforcement plate to both the right and left strut tower as outlined in this bulletin.
NOTE:
For claim submission information, see Safety Campaign Notice # SC-15
AFFECTED VIN RANGE:
PARTS INFORMATION:
REMOVE (PARTIAL) STRUT ASSEMBLY
1. Hoist vehicle, allowing front suspension to hang free about 1 foot off the ground.
2. Remove the Strut Tower Crossbar.
CAUTION:
Hold strut so that it will not fall off when the 3 Strut Support Nuts are removed.
3. Allow the Strut Assembly to hang free.
4. Set the countermeasure front Strut Stay on top of the Strut Tower; matching the 3 Strut Stud Holes. Mark the location of the fourth bolt hole using the counter-measure Strut Stay as a template. Drill a 12 mm. hole through the Strut Tower at the marked location and touch-up paint the area to prevent rust.
CAUTION:
Ensure the fourth bolt hole is toward the engine lie and the front of the vehicle.
5. Fit the Front Strut Reinforcement into the Strut Tower through the Outer Wheel Well and mark its position and contact area. Scrape the undercoating from the contact area as shown in the illustration. Spray primer on the scraped area to prevent rust. Use care to prevent overspray. (Left side shown as an example.)
6. Assemble the Front Strut Stay and Front Strut Reinforcement using the supplied bolt. Torque bolt to 36.8 lb-ft (50 Nm, 5.0 Kg-m)
7. Replace the upper Strut Support with the new supplied part; torquing the Strut Nut (shock absorber upper mount nut) to 61.5 lb-ft (85 Nm, 8.5 Kg-m)
8. Reinstall the Strut Assembly and Strut Bar onto the Strut Tower using the supplied new Strut Support Nuts (P/N # 08316-20083) and torque to 18.0 lb-ft (25 Nm, 2.5 Kg-m).
9. Clean the Strut Bar of any grease or oil and place the RED W2 sticker on the forward facing surface of the Strut Bar.
Disclaimer:
Disclaimer