Steering/Suspension - Front End Knock/Clunk On Bumps
TECHNICALBulletin No.: 09-03-08-008A
Date: May 26, 2010
Subject: Knock, Clunk or Click Noise from Front Suspension Over Small Bumps (Replace Front Lower Control and Caster Arms)
Models:
2008-2009 Pontiac G8
Attention:
This bulletin is intended to correct a condition for front end knock, clunk or clicking. Vehicles previously repaired as part of Customer Satisfaction Program 09203A are to follow a different repair procedure as outlined under the Correction section below.
Supercede:
This bulletin is being revised to update the Parts Information. A front lower control arm kit is now available that services all four lower control arms as outlined in this Service Bulletin. Please discard Corporate Bulletin Number 09-03-08-008 (Section 03 - Suspension).
Condition
Some customers may comment on a clunk, knock or click noise from the front suspension over small bumps.
Cause
The rubber "boot" over the front end lower control arm ball joint may have become dislodged or torn compromising the seal. Moisture inside the ball joint seal may cause corrosion, shortening the service life of the component.
Correction
Notice
Before replacing any components under the terms of this bulletin, you must confirm the past service history of the vehicle. Please use GMVIS (dealers using WINS) or the Investigate Vehicle History link (dealers using GWM) to confirm if the vehicle was previously repaired under Customer Satisfaction Program 09203A. If the vehicle was repaired under this service action, ONLY replace the front control arm found to be the source of the noise and claim the applicable labor operation for that part as outlined in SI and the labor time guide.
Vehicles not identified in Customer Satisfaction Program 09203A (or not repaired during its duration) and found to have one or more of the rubber boots improperly sealing should have all four front control arms replaced.
Front Lower Control and Caster Arm Replacement (Both Sides)
The instructions below detail replacement of all four front lower control and caster arms.
Danger
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
2. Remove the front wheels. Refer to Tire and Wheel Removal and Installation in SI.
3. Loosen the control arm to steering knuckle retaining nut (1) about two turns.
4. Using the J 42188-B Ball Joint Separator (1), disconnect the control arm (2) from the steering knuckle (3).
5. Remove the control arm to steering knuckle retaining nut (1).
6. Separate the control arm (2) from the steering knuckle (3).
7. Remove the control arm to subframe retaining bolt.
8. Remove and discard the front control arm (3) from the subframe (2).
9. Install the NEW front control arm (3) to the subframe (2).
Warning
The existing control arm bolts and nuts may be reused for this procedure. You MUST remove all traces of the original adhesive patch on the bolt. Clean the threads of the bolt with denatured alcohol, GM Low VOC Brake Cleaner GM P/N 12378392 or equivalent, and allow to dry. Before Installation, apply threadlocker GM P/N 12345493 (in Canada, use 10953488) or blue, medium LOCTITE(TM) 242.
Note
The NEW front control arm to subframe retaining bolt (1) must not be fully tightened at this stage.
10. Install the NEW front control arm to subframe retaining bolt (1).
11. Install the NEW control to the steering knuckle.
12. Install the NEW front control arm (1) to steering knuckle retaining nut (2).
Important
Use the J 45059 Torque/Angle Tool when tightening the following:
Tighten
- First Pass: Tighten the nut to 40 Nm (30 lb ft).
- Final Pass: Tighten the nut an additional 60 degrees.
13. Loosen the caster arm to steering knuckle retaining nut (1) about two turns.
14. Using the J 42188-B Ball Joint Separator (3), disconnect the caster arm (1) from the steering knuckle (2).
15. Remove the caster arm to steering knuckle retaining nut (3). Mark keyway slot on the bushing relative to the cradle.
16. Separate the caster arm (1) from the steering knuckle (2).
17. Remove the caster arm to subframe retaining bolt.
18. Remove and discard the caster arm from the subframe.
19. Install the NEW caster arm to the subframe. Line up the keyway slot on the bushing to previous mark on the cradle.
20. Install the front caster arm to the subframe retaining bolt.
21. Install the new front caster arm to the steering knuckle.
Note
The caster arm to subframe retaining bolt is not to be fully tightened at this stage.
22. Install the NEW caster arm (1) to the steering knuckle (2) retaining nut.
Important
Use the J 45059 Torque/Angle Tool when tightening the following
Tighten
- First Pass: Tighten the nut to 50 Nm (37 lb ft).
- Final Pass: Tighten the nut an additional 60 degrees.
23. Repeat Steps 3-20 for the other side of the vehicle then continue below.
24. Install the front wheels. Refer to Tire and Wheel Removal and Installation in SI.
25. Lower the vehicle.
26. Bounce the vehicle several times to settle the suspension.
27. Check and adjust the wheel alignment. Refer to Front End Alignment in SI.
28. Tighten the NEW control arm to subframe retaining bolt.
Important
Use the J 45059 Torque/Angle Tool when tightening the following:
Tighten
- First Pass: Tighten the bolts to 40 Nm (30 lb ft).
- Final Pass: Tighten the bolts an additional 120 degrees.
29. Tighten the NEW caster arm to subframe retaining bolt.
Important
Use the J 45059 Torque/Angle Tool when tightening the following:
Tighten
- First Pass: Tighten the bolts to 40 Nm (30 lb ft).
- Final Pass: Tighten the bolts an additional 120 degrees.
Parts Information
Warranty Information
For vehicles repaired under warranty, use:
Note
If the vehicle was previously repaired under Customer Satisfaction Program 09203A, ONLY replace the front control arm found to be the source of the noise and claim the applicable labor operation for that part as outlined in SI and the Labor Time Guide.
Disclaimer