Suspension - Front End Clicking/Popping On Accel./Braking

09-077

March 9, 2012

Applies To:
*2009-10 Pilot - ALL
2011 Pilot 2WD - From VIN 5FNYF3H..BB000001 thru 5FNYF3H..BB017216
2011 Pilot 4WD - From VIN 5FNYF4H..BB000001 thru 5FNYF4H..BB028676*

Clicking From the Front Suspension While Accelerating or Braking, or Leak
From the Front Suspension Rear Lower Arm Bushing

(Supersedes 09-077, Clicking From the Front Suspension While Accelerating or Braking, dated November 20, 2009, to revise the information marked by the black bars)

*REVISION SUMMARY

^ Under Applies To, some 2011 models were added.

^ Under PARTS INFORMATION, the lower arm bushing bracket set part number has changed.

^ Under TOOL INFORMATION, the ball joint remover tool number was changed.*

SYMPTOM

There are one or more clicking or popping noises coming from the front suspension while accelerating or braking, or the front suspension rear lower arm bushing is leaking.

PROBABLE CAUSE

The front suspension rear lower arm bushing bracket is faulty.

CORRECTIVE ACTION

Replace both front suspension rear lower arm bushing brackets, and check the wheel alignment.

PARTS INFORMATION

*Lower Arm Bushing Bracket Set:
P/N 04513-SZA-010*

Ball Joint Castle Nut (two required):
PIN 90365-STX-A00

Lower Arm Flange Bolt, 14 mm (four required):
P/N 9011 8-STX-A00

Lower Arm Flange Bolt, 16 mm (two required):
P/N 90118-SJC-A00

TOOL INFORMATION

*Ball Joint Remover, 32 mm:
T/N 07MAC-5L00102*

Ball Joint Thread Protector, 14 mm:
T/N 071AF-53VA000

WARRANTY CLAIM INFORMATION





The normal warranty applies.

Failed Part: P/N 51350-SZA-A02

Defect Code: 01102

Symptom Code: 04201

Skill Level: Repair Technician

DIAGNOSIS

Listen for one or more clicking or popping noises coming from the front suspension while accelerating from a moderate stop (between normal and abrupt), or while braking. Inspect the front suspension rear lower arm bushing for leakage.

^ If you hear the noise, or the bushing is leaking, go to REPAIR PROCEDURE.

^ If you don't hear the noise, and the bushing is not leaking, continue with normal troubleshooting.

REPAIR PROCEDURE

1. Raise the vehicle on a lift.

2. Remove the front wheels.





3. Remove the lock pin from the lower arm ball joint, then remove the castle nut.

4. Disconnect the lower arm ball joint from the knuckle using the ball joint thread protector and the ball joint remover.

NOTE:

^ Be careful not to damage the ball joint boot when installing the remover.

^ Do not force or hammer on the lower arm, or pry between the lower arm and the knuckle. You could damage the ball joint.





5. Remove the mounting bolt from the rear side of the stabilizer bar bushing holder.

6. Remove the 14 mm and 16 mm lower arm mounting bolts, then remove the lower arm.





7. Remove the lower arm stops.





8. Remove the self-locking nut from the rear lower arm bushing, then remove the rear lower arm bushing bracket.





9. Install a new bushing bracket on the lower arm, then align the angle of the lower arm center line and the lower edge line of the bushing bracket as shown.

10. Install a new self-locking nut, then tighten the nut to 162 Nm (119 lb-ft).

11. Install the lower arm stops.





NOTE:
Align the slot on the lower arm stop with the lug portion on the front side of the lower arm bushing.

12. Install the lower arm with new bolts:

^ Lightly tighten the bolts.

^ Raise the suspension to load it with the vehicle's weight before fully tightening the bolts. Do not place the jack against the ball joint on the lower arm.

^ Torque the 14 mm bolts to 93 Nm (69 lb-ft), and torque the 16 mm bolt to 162 Nm (119 lb-ft).

^ Install the mounting bolt on the rear side of the stabilizer bar bushing holder, and torque it to 39 N.m (29 lb-ft).

13. Degrease the threaded section and the tapered portion of the ball joint pin, the ball joint connecting hole, and the threaded section and the mating surfaces of the castle nut. Connect the ball joint to the lower arm, being careful not to damage the ball joint boot when connecting the knuckle.

14. Torque the castle nut to the lower torque specification (103-113 N.m [76-83 lb-ft]), then tighten it only far enough to align the slot with the ball joint pin hole. Do not align the castle nut by loosening it. Insert the lock pin.

15. Repeat steps 3 thru 14 on the other side of the vehicle.

16. Clean the mating surfaces on the brake discs and the inside of the wheels, then install the front wheels.

17. Check the front wheel alignment, and adjust it if needed.





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