Pop or Clunk from Front End When Driving over Bumps in Cold Weather – 2012-2014 Honda Odyssey

A14-016
September 28, 2016
04967 Version 3

 

Pop or Clunk from Front End When Driving over Bumps in Cold Weather

Supersedes 14-016, dated October 8, 2014; to revise the information highlighted in yellow

 

REVISION SUMMARY

Under PARTS INFORMATION, a part number was updated.

 

AFFECTED VEHICLES

Year	Model	Trim	VIN Range
2012	Odyssey	ALL	5FNRL5H..CB088500 thru 5FNRL5H..CB999999
2013	Odyssey	ALL	ALL
2014	Odyssey	ALL	5FNRL5H..EB000001 thru 5FNRL5H..EB060508

 

SYMPTOM 

In below-freezing weather, there is a pop or clunk from the front of the vehicle while going over a bump.

 

POSSIBLE CAUSES

The front bump stops have loosened and are moving inside the top mounting cap.

 

CORRECTIVE ACTION

Replace both front bump stops.

 

PARTS INFORMATION

Part Name	Part Number	Quantity
Front Bump Stop	51722-TK8-A21	2
Flange Bolt (16 X 68 mm)	90120-SHJ-A00	4
Nut (12 mm)	90213-SHJ-L01	2
Flange Nut (10 mm)	90304-S10-024	6
Flange Nut (16 mm)	90382-SP0-003	4

 

WARRANTY CLAIM INFORMATION

The normal warranty applies.

Operation Number	Description	Flat Rate Time	Template ID	Failed Part Number
4141E1	Install new bump stops on both sides (includes test drive and alignment).	2.1 hours	14-016A	51722-SHJ-A02

 

Defect Code: 06201
Symptom Code:  04201
Skill Level: Repair Technician

 

DIAGNOSIS

1. With the vehicle cold-soaked and the ambient temperature at 23º F or below, drive the vehicle over a road with small bumps.
   • If a pop or clunk (similar to a mallet hitting a solid metal piece) is heard from the front struts, park the vehicle inside the shop and wait about 30 minutes to warm it up, then continue with step 2.
   • If no noise is heard, this bulletin does not apply. Continue with normal troubleshooting.
2. After the suspension components have warmed up for 30 minutes, drive the vehicle on the same portion of the road where you heard the pop or clunk.
   • If there is no noise from the front suspension, continue to REPAIR PROCEDURE.
   • If the same noise is heard, this bulletin does not apply. Continue with normal troubleshooting.

 

REPAIR PROCEDURE

1. Raise and support the vehicle.
2. Remove the front wheel.
3. Remove the wire guide rubber and the clip from the damper. Do not disconnect the wheel speed sensor connector.

 

4. Remove the brake hose bracket from the damper.
5. Remove the flange nut while holding the joint pin with a hex wrench, and disconnect the stabilizer link from the damper.

 

6. Remove the damper pinch bolts and flange nuts from the damper.

NOTE: Do not allow the knuckle to rotate too far outward, or the driveshaft inboard joint may come apart.

 

7. Remove the cowl top wiper cover, then remove the flange nuts from the top of the damper. Do not let the damper/spring drop down under its own weight.

 

8. Remove the damper/spring.

 

9. Compress the damper spring, then remove the self-locking nut while holding the damper shaft with a hex wrench. Do not compress the damper spring more than necessary to remove the self-locking nut.

 

10. Release the pressure from the strut spring compressor, then disassemble the damper.
11. Install the new bump stop.
12. Reassemble the damper using a new self-locking nut. Torque the nut to 70 N∙m (52 lb-ft).
13. Reinstall the damper assembly onto the vehicle using the new flange nuts and pinch bolts. Torque the flange nuts to 69 N∙m (51 lb-ft) and the pinch bolts to 175 N∙m (129 lb-ft).
14. Reconnect the stabilizer link to the damper. Torque the bolt to 79 N∙m (58 lb-ft).
15. Install the brake hose bracket to the damper. Torque the bolt to 21 N∙m (15 lb-ft).
16. Repeat steps 2 through 15 on the other damper assembly.
17. Do the front wheel alignment.

END