Suspension - Front Suspension Tapping Noise
SUSPENSIONSU003-02
REVISED
October 31, 2002
Title:
FRONT UPPER SUSPENSION NOISE
Models:
'03 Corolla & Matrix
TSB REVISION NOTICE:
The information contained in this TSB was revised on October 31 2002.
The previous TSB should be discarded.
Introduction
Some 2003 model year Corolla and Matrix vehicles may exhibit a tapping noise from the front upper suspension area. Occasionally this noise may be interpreted as an instrument panel rattle noise. Use the following instructions to repair the noise.
Applicable Vehicles
2003 model year Corolla and Matrix vehicles produced before the VINs below.
Production Change Information
Parts Information
Warranty Information
Applicable Warranty * :
This repair is covered under the Toyota Comprehensive Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific complaint.
Repair Procedure
1. Remove Front Wheel
2. Disconnect Front Stabilizer Link Assembly
Remove the nut and disconnect the front stabilizer link assembly from the front shock absorber assembly.
3. Disconnect Front Flexible Hose
A. W/ABS:
Remove the bolt, disconnect the brake flexible hose and front speed sensor.
B. W/O ABS:
Remove the bolt, disconnect the brake flexible hose.
4. Remove Front Shock Absorber With Coil Spring
A. Remove the 2 bolts and nuts on the lower side of the front shock absorber assembly.
NOTE:
When removing the bolt, stop the bolt from rotating and loosen the nut.
B. Remove the 3 nuts on the upper side of the front shock absorber assembly.
C. Remove the front shock absorber with the coil spring.
5. Prepare Insulating Material
A. Locate the 2 mm EPT Sealer in the Wind Noise kit (P/N 08231-00810)
B. Cut 3 pieces of EPT Sealer per side of vehicle (6 pieces total) to the following dimensions:
EPT Dimensions:
L: 100 mm (4 in.)
W: 13 mm (0.5 In.)
T: 2 mm (0.08 in.)
6. Apply EPT Sealer To Upper Suspension Mount
NOTE:
Avoid applying the EPT sealer within 15 mm (0.6 in.) from the edge of the upper suspension mount bolts.
7. Install Front Shock Absorber With Coil Spring
A. Install the shock absorber with the two bolts.
B. Install the 3 nuts to the upper side of the front shock absorber with coil spring.
Torque: 39 N.m (398 kgf.cm, 29 ft.lbf)
C. Install the 2 bolts and nuts to the lower side of the front shock absorber with coil spring.
Corolla Torque: 153 N.m (1,560 kgf.cm, 113 ft.lbf)
Matrix Torque: 220 N.m (2,243 kgf.cm, 162 ft.lbf)
NOTE:
When installing the bolt, stop the bolt from rotating and torque the nut.
8. Install Front Flexible Hose
A. W/ABS:
Install the brake flexible hose and front speed sensor with the bolt.
Torque: 29 N.m (296 kgf.cm, 21 ft.lbf)
B. W/O ABS:
Install the brake hose with the bolt.
Torque: 29 N.m (296 kgf.cm, 21 ft.lbf)
9. Install Front Stabilizer Link Assembly
Install the front stabilizer link assembly with the nut.
Torque: 74 N.m (755 kgf.cm, 55 ft.lbf)
NOTE:
If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud.
10. Install Front Wheel
Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
11. Inspect and Adjust Front Wheel Alignment