A12-082
September 17, 2013
Applies To:
2008–12 Accord – ALL
2010–13 Crosstour – ALL
Front Suspension Clunk in Hot Weather
(Supersedes 12-082, dated June 4, 2013, to revise the information marked by the black bars)
REVISION SUMMARY
In Applies To, 2013 Crosstour was added.
SYMPTOM
A clunk is heard in the front suspension while driving over irregular surfaces and in hot weather. The noise goes away temporarily when the vehicle is lifted in the air (the suspension is allowed to hang) and then returned to the ground.
POSSIBLE CAUSE
High ambient temperatures cause the grease to redistribute to the bottom of the ball joint, resulting in a stick-slip knock.
CORRECTIVE ACTION
Replace both of the front lower ball joints with updated service parts made to address this specific symptom. If the ball joints were previously replaced, then replace both front knuckle assemblies.
PARTS INFORMATION
| Accord/ Crosstour Parts Description | Part Number | QTY |
| Lower Ball Joint | 51220-TA0-306 | 2 |
| Ball Joint Cotter Pin | 94201-30220 | 2 |
| Spindle Nut | 90305-S3V-A11 | 2 |
| Tie Rod Cotter Pin | 94201-30220 | 2 |
| Snap Ring
(if knuckle replaced) | 90681-SJK-000 | 1 |
| Upper Arm Ball Joint Cotter Pin (if knuckle replaced) | 94201-20220 | 2 |
| Wheel Bearing
(if knuckle replaced) | 44300-TA0-A61 | 2 |
| Accord Parts Description | Part Number | QTY |
| Knuckle Assembly, Left
(only if prior ball joint replaced) | 51215-TA0-Y60 | 1 |
| Knuckle Assembly, Right
(only if prior ball joint replaced) | 51210-TA0-Y60 | 1 |
| Crosstour Parts Description | Part Number | QTY |
| Knuckle Assembly, Left
(only if prior ball joint replaced) | 51215-TP6-Y00 | 1 |
| Knuckle Assembly, Right
(only if prior ball joint replaced) | 51210-TP6-Y00 | 1 |
| Tool Description | Part Number |
| Adapter G | 07XAF-001050A
07XAF-00105B |
| Ball Joint Remover, 28 mm | 07MAC-SL0A202 |
| Ball Joint Thread Protector
mm | 07AAF-SECA120 |
| Ball Joint Thread Protector
mm | 07AFF-SDAA100 |
| Ball Joint Thread Protector
mm | 07AAE-SJAA100 |
| Ball Joint Tool Kit | 07AAF-TL2A150
(contains the following parts) |
| 07AAF-TL2A100 | |
| 07AAF-TL2A200 | |
| 07AAF-TL2A300A | |
| 07AAF-TL2A300B | |
| 07AAF-TL2A400 | |
| Bearing Driver Attachment | 07746-0010600 |
| C-Frame | OTC7248
(or commercially available) |
| Driver Handle | 07749-0010000 |
| Oil Seal Driver Attachment
mm | 07ZAD-PNAA100 |
| Hub Assembly/
Disassembly Pin, 42 mm | 07GAF-SD4A100 |
| Support Base | 07965-SD90100 |
WARRANTY CLAIM INFORMATION
The normal warranty applies.
*Only one of the following repairs below will apply.
| OP# | Description | FRT |
| 4151A9 | Replace both front knuckles. | 2.3 |
| A | Alignment – add | 0.4 |
| OP# | Description | FRT |
| 4161C0 | Replace both front ball joints. | 1.5 |
| A | Alignment – add | 0.4 |
Failed Part: P/N 51220-TA0-A02
Defect Code: 07409
Symptom Code: 04201
Skill Level: Repair Technician
DIAGNOSIS
Raise the vehicle on a lift high enough to let the suspension hang. Lower the vehicle, then test-drive it to confirm the clunking noise is gone.
- If the noise is gone, go to REPAIR PROCEDURE.
- If the noise is still there, this bulletin does not apply. Continue with normal troubleshooting.
REPAIR PROCEDURE
- Raise and support the vehicle.
NOTE: Do this repair to both sides of the front suspension.
- Clean the top surface of both lower ball joints in the front knuckles and inspect for a paint mark, indicating prior replacement.
- If there is a paint mark, replace both front knuckle assemblies.
NOTE: Ball joints can only be replaced one time on a knuckle and then it requires replacement.
- If there is no paint mark, replace both lower ball joints.
- Remove the wheel speed sensor and its harness brackets at the knuckle assembly and at the damper assembly. Do not disconnect the wheel speed sensor connector.
- Remove the brake caliper bracket mounting bolts, then remove the caliper assembly from the knuckle. To prevent damage to the caliper assembly or the brake hose, use a short piece of wire to hang the caliper assembly from the undercarriage. Do not twist the brake hose excessively.
- Pry up the stake on the spindle nut, then remove the nut.
- Remove the front brake disc.
- Remove the brake flathead screws.
- Remove the brake disc from the front hub.
- Check the front hub for damage and cracks.
NOTE: If the brake disc is stuck to the front hub, thread two 8 x 1.25 mm bolts into the brake disc to push it away from the front hub. Turn each bolt 90° at a time to prevent the brake disc from binding.
- Remove the cotter pin from the tie-rod end ball joint, then remove the nut.
NOTE: During installation, install a new cotter pin after tightening the nut, and bend its end as shown.
- Disconnect the tie-rod end ball joint from the knuckle using the ball joint thread protector and the ball joint remover.
- Remove the cotter pin from the knuckle ball joint, then remove the castle nut.
NOTE: During reassembly, insert a new cotter pin into the ball joint pin hole from the front to the rear of the vehicle, and bend its end as shown. Check the ball joint pin hole direction before connecting the ball joint.
- Disconnect the knuckle ball joint from the lower arm using the ball joint thread protector and ball joint remover.
NOTE: Do not force or hammer on the lower arm or pry between the lower arm and the knuckle.
- If replacing the knuckle assemblies, go to step 13.
- If using existing knuckle assemblies, go to step 15.
- Remove the cotter pin from the upper arm ball joint, then remove the castle nut.
NOTE: During reassembly, install a new cotter pin into the ball joint pin hole from the front to the rear of the vehicle, and bend its end as shown. Check the ball joint pin hole direction before connecting the ball joint.
- Disconnect the upper arm ball joint from the knuckle using the ball joint thread protector and the ball joint remover.
- Pull the knuckle outward and separate the outboard joint from the front hub using a soft face hammer.
NOTE: Do not pull the driveshaft end outward. The driveshaft inboard joint may come apart. During installation, apply grease to the mating surfaces of the wheel bearing and the driveshaft outboard joint.
- Remove the front knuckle ring from the knuckle. Inspect it for deformation and damage, and replace it if needed.
NOTE: When installing the front knuckle ring, position the knuckle ring notch portion toward the cutout near the ball joint in the knuckle, and align the center of the knuckle ring ledge portion with the center of the wheel speed sensor hole on the knuckle.
- Separate the hub from the old knuckle using the hub dis/assembly pin and a hydraulic press. Hold the knuckle with the hydraulic press attachment or equivalent tool. Be careful not to damage or deform the splash guard. Hold onto the hub to keep it from falling when pressed clear.
- Press out the wheel bearing inner race of the hub using the hub dis/assembly pin, a commercially available bearing separator, and a hydraulic press.
- Remove the snap ring and the splash guard from the knuckle.
NOTE: This old wheel bearing will be used to assist in the installation of the new wheel bearing into the new knuckle assembly.
- Press a new wheel bearing into the new knuckle using the old bearing, a steel plate, the attachment, the support base, and a press.
NOTE:
- Install the new wheel bearing with the wheel speed sensor magnetic encoder (brown color), toward the inside of the knuckle.
- Remove any oil, grease, dust, metal debris, and other foreign material from the magnetic encoder surface.
- Keep any magnetic tools away from the magnetic encoder surface.
- Be careful not to damage the magnetic encoder surface when you insert the new wheel bearing.
NOTE: Inspect the front knuckle ring for damage or deformation prior to installation, and replace it if necessary.
Position the knuckle ring notch portion toward the cut out near the ball joint in the knuckle, and align the center of the knuckle, and align the center of the knuckle ring ledge portion with the center of the wheel speed sensor hole on the knuckle.
- Install the splash ring and the splash guard.
- Install the splash guard, and tighten the screws to the specified torque, then remove the knuckle assembly from the vise.
- Install the hub onto the new knuckle assembly using the driver handle, the attachment, the support base, and a hydraulic press. Be careful not to damage the splash guard.
- Install the new knuckle assembly, then go tostep 35.
- Remove the boot clip, then remove the boot from the ball joint, and wipe the grease off the exposed portion.
- Clean and wipe off the hub center, then install the attachments (07AAF-TL2A300-A and B) of the ball joint tool kit through the hub center. Position the projection of the attachment (07AAF-TL2A300-B) toward the lower side of the knuckle. Tighten it into place by hand.
NOTE: Make sure that the flat part of the attachment is parallel to the top of the knuckle ball joint.
- Position the ball joint tool kit, the adapter G, and the C-frame OTC7248 (commercially available) on to the knuckle ball joint.
NOTE: Make sure the attachments are installed securely.
- Tighten the pressure bolt of the C-frame, and remove the knuckle ball joint.
NOTE: When tightening the pressure bolt, secure the knuckle and the outboard joint.
- Remove the ball joint tool attachments (07AAF-TL2A300-A and B) from the hub.
- Set the new ball joint into the knuckle.
NOTE: Confirm that the new lower ball joint is stamped with a P, indicating a part to resolve clunk noise in high ambient temperature conditions.
- Position the ball joint tool kit and the C-frame OTC7248 (commercially available) to the ball joint. Tighten the pressure bolt of the C-frame until the knuckle ball joint shoulder is fully seated in the knuckle.
NOTE: Make sure the attachments are installed securely. When tightening the pressure bolt, make sure the knuckle and the ball joint are properly aligned.
- Using a yellow oil-based paint marker, paint the top of the knuckle lower ball joint.
NOTE: The paint mark is used to identify a knuckle that has had prior ball joint replacement. Always replace the knuckle as an assembly if the ball joint to be replaced has a paint mark.
- Install the remaining parts in reverse order of removal, and note these items:
- First, install all of the components, and lightly tighten the bolts and the nuts, then raise the suspension to load it with the vehicle’s weight before fully tightening it to the specified torque. Do not place the jack against the ball joint pin of the knuckle.
- Be careful not to damage the ball joint boot when connecting the knuckle.
- Before connecting the ball joint, degrease the threaded section, the tapered portion of the ball joint pin, and the ball joint connecting hole, the threaded section, and the mating surfaces of the castle nut.
- Torque the castle nut to the lower torque specification, 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.
- Use a new spindle nut on reassembly.
- Before installing the spindle nut, apply a small amount of engine oil to the seating surface of the nut. After tightening, use a drift to stake the spindle nut shoulder against the driveshaft.
- Before installing the wheels, clean the mating surfaces between the brake disc and the inside of the wheel.
- If the knuckle hub assembly was replaced, before installing the brake disc, clean the mating surfaces between the front hub and the inside of the brake disc.
- Check the wheel alignment, and adjust it if necessary.
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