Body/Frame - Pop/Click From Vehicle Rear On Bumps
10-019February 1, 2011
Applies To:
2008-09 Accord Sedan - All VINS beginning with 1HG and 5KB
Popping or Clicking From the Left Rear or Right Rear Jack Point (Supersedes 10-019, dated May 7, 2010, to revise the information marked by the asterisks)
*REVISION SUMMARY
Under DIAGNOSIS, the reference service bulletin number was changed.*
SYMPTOM
There is a popping or clicking from the left rear or right rear when driving over bumps or through dips.
PROBABLE CAUSE
As the body flexes, burrs from spot welds in the rear jacking points contact other sheetmetal, causing a popping or clicking noise.
CORRECTIVE ACTION
Install a wedge between the sheetmetal panels (in the inner side sill) that make up the jack point.
REQUIRED MATERIALS
3M Super Weatherstrip and Gasket Adhesive:
P/N 3M-08008
(One tube repairs about 20 vehicles.)
TOOL INFORMATION
Body Wedge Installation Tool Kit: TIN O7AAD-TA5A140
(Includes one wedge, installation tool, acid brush
extension, and acid brush)
Additional Body Wedges (Pack of four):
P/N 07AAK-TA5A140
WARRANTY CLAIM INFORMATION
The normal warranty applies.
Failed Part: P/N 04631-TA0-A00ZZ
Defect Code: 02401
Symptom Code: 04201
Skill Level: Repair Technician
DIAGNOSIS
Connect a ChassisEAR around the suspected area, then test-drive the vehicle to confirm that the noise is coming from the left rear or right rear jacking point. If needed, refer to Service Bulletin 00-063, Steelman ChassisEAR Diagnostic Tool.
REPAIR PROCEDURE
1. On the affected side, remove the middle floor undercover bolt from the fenderwell, then fold the undercover back out of the way.
2. Remove the grommet from the wheelwell and the grommet from the bottom of the side sill. Shine a light through the side sill grommet hole so you can see inside through the wheelwell grommet hole.
3. Looking through the grommet hole, you will see the sheetmetal panels that make up the jack point. A good jack point will show a noticeable gap between the sheetmetal panels. In a faulty jack point the gap will be very small, or the panels will be touching.
4. Using an acid brush and an extension, apply the adhesive through the wheelwell grommet hole and between the sheetmetal at the insertion point shown. Allow the adhesive to become tacky before installing the wedge.
5. Mount the wedge onto the end of the installation tool, and apply a generous amount of adhesive to both sides. Allow the adhesive to become tacky before installation.
6. Insert the wedge through the wheelwell hole and into the insertion point by hand. Make sure the stop on the installation tool is pointing down. (For clarity, the wedge in the illustration is shown without adhesive.)
7. Use a hammer to drive the wedge securely into the insertion point until you feel the stop come in contact with the sheetmetal.
8. Gently twist and wiggle the tool from side to side to release the wedge.
9. Reinstall the grommets, apply commercially available undercoat to the grommets, and secure the middle floor undercover in its original position.
10. If noise is coming from both sides, repeat steps 1 through 9 on the other side.
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