Knocking Squeaking Noise from Front Shock Absorber, Creaking Noise From Front Lower Arm Bushing – 2013-2016 Mazda

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Subject:

MULTI-MODEL – KNOCKING / SQUEAKING NOISE FROM FRONT SHOCK ABSORBER, CREAKING NOISE FROM FRONT LOWER ARM BUSHING

Bulletin No: 02-010/16
Last Issued: 07/21/2016

 

BULLETIN NOTE

This bulletin supersedes the previously issued bulletin(s) listed below: The changes are noted in Red beside the change bars.

Previously issued TSBs: Date issued:
02-010/16 04/05/2016, 03/10/2016
02-006/16 02/23/2016
02-003/15 12/17/2015 and 02/04/2015
02-001/15 11/20/2015 and 01/14/2015
02-005/14 12/12/2014
02-005/13 08/24/2013 and 11/11/2013

 

APPLICABLE MODEL(S)/VINS

2016 CX-3 vehicles with VINs lower than JM1 DK ****** 136727 (produced before March 07, 2016)

2013-2016 CX-5 vehicles with VINs lower than JM3 KE ****** 742261 (produced before November 16, 2015)

2014-2016 Mazda6 vehicles with VINs lower than JM1 GJ ****** 459655 (produced before November 16, 2015)

 

DESCRIPTION

Some vehicles may exhibit a knocking / squeaking noise from the front shock absorber when driving on rough roads and/or when turning the steering wheel while the vehicle is stopped.

The noise may be due to:

  • upper front strut bearing (A) damage. (CX-5 and Mazda6)
  • stick/slip between the front strut bearing and coil spring. (CX-3, CX-5 and Mazda6)
  • the bump stopper (C) may be contacting the strut bearing when the front shock absorber is compressed, causing a popping noise. (Mazda6 only)
  • The front lower arm bushing (D) is making a stick-slip noise in wet road conditions. (CX-5 and Mazda6)
Front Shock Absorber Front Lower Arm
Front Shock Absorber Front Lower Arm

 

To eliminate the noise, the following mass-production changes have been made:

  1. The material and production method of the front strut bearing (A) has been changed. (CX-5 and Mazda6)
  2. A protector has been installed onto the coil spring. (CX-5 and Mazda6)
  3. The shape of the bump stopper (C) will be modified in the future. (Mazda6 only)
  4. The shape of the coil spring has been changed. (CX-3 only)
  5. Friction of the lower arm bushing has been reduced by adding a dry coating. (CX-5 and Mazda6)

NOTE: The piston rod nut (B) requires replacement.

Customers having this concern should have their vehicle repaired using the following repair procedure.

 

REPAIR OUTLINE

  1. Use Special Service Tool (SST) ChassisEAR / EngineEAR II Combo JSP06608 or Wireless ChassisEAR JSP97202 to confirm noise is coming from the front suspension when driving over bumps and/or turning the steering wheel while the vehicle is stopped:

NOTE: SST JSP06608 and JSP97202 are available for purchase on Mazda E-Store.

ChassisEAR / EngineEAR II Combo JSP06608 or

Wireless ChassisEAR JSP97202

ChassisEAR / EngineEAR II Combo JSP06608 Wireless ChassisEAR JSP97202

 

  1. Was the noise verified?
    • Yes – Use the table below to determine if the subject vehicle is a Type A, Type B, Type C, Type D, or Type E vehicle.
    • No – This does not apply.
Model Type A Type B Type C Type D Type E
Mazda6 JM1GJ****** 100001- 121430 121431- 404928 404930- 459654 459655- 999999
CX-5 JM3KE****** 100001 – 343673 343674 – 615843 615844 – 742260
CX-3 JM1DK****** 100001- 199998

 

  1. Use the table below to identify the appropriate repair.
Repair

(Perform On Both Sides)

Type A Type B Type C Type D Type E

1. Inspect the front strut bearing for damage. If damaged, replace it.

Perform Do Not Perform Do Not Perform Do Not Perform Do Not Perform
2. Install the protector onto the coil spring. (Refer to “Protector Installation Procedure”. Perform Perform Do Not Perform Do Not Perform Perform
3. Replace the lower arm bushing. Perform Perform Perform Do Not Perform Do Not Perform

4. Replace the bump stopper. (Mazda6 Only)

Perform Perform Perform Perform Do Not Perform

 

NOTE:

CAUTION: It is not necessary to adjust the front wheel alignment because the front shock absorber and the mounting rubber are not replaced. However, make sure to install the mounting rubber to the original position.

 

REPAIR PROCEDURE

Inspect Front Strut Bearing for damage (For Vehicle Type A only)

  1. Remove the front strut bearing and coil spring according to the MS3 online instructions or the Workshop Manual (section 02-13 FRONT SHOCK ABSORBER AND COIL SPRING DISASSEMBLY/ASSEMBLY).
  2. Replace the front strut bearing if damaged*.
Strut Bearing Strut Bearing

 

Install Protector onto Coil Spring (For Vehicle Type A, B and E)

Coil Spring Protector (A) Installation:

Coil Spring Protector (A)

  1. Starting from the top of the coil spring, degrease the spring 1.5 coils downward.
  2. Cut a thin strip of paper to 138 mm in length (or use a cloth type measuring tape).

NOTE: For CX-3, use 130 mm in length.

  1. Place the strip of paper (or cloth measuring tape) along the inner side of the coil spring starting at point (A).
  2. Mark the spot on the spring where (B) is. (B) is the starting point for the protector installation.

Install the protector (A) onto the coil spring aligning the end (slant cut side) with the marking at spot (B)

  1. Install the protector (A) onto the coil spring aligning the end (slant cut side) with the marking at spot (B).

NOTE: Install the protector so the gap (C) is evenly aligned around the outer edge of the coil spring.

Install the protector so the gap (C) is evenly aligned around the outer edge of the coil spring

 

  1. The inner side of the protector contains adhesive glue. After installing the protector onto the spring, press the inner side to firmly adhere it to the spring.
  2. Assemble the coil spring to the strut assembly and make sure the protector is seated onto the bearing even when the shock absorber is fully extended.

 

Replace Bump Stopper (For all Mazda6 vehicles)

  1. Remove the front strut bearing and coil spring according to MS3 online instructions or the Workshop Manual (section 02-13 FRONT SHOCK ABSORBER AND COIL SPRING DISASSEMBLY/ASSEMBLY).
  2. Replace the bump stopper (C).

bump stopper (C)

  1. Reinstall the front strut bearing and coil spring according to MS3 online instructions or the Workshop Manual (section 02-13 FRONT SHOCK ABSORBER AND COIL SPRING DISASSEMBLY/ASSEMBLY).
  2. Repeat Steps 1 – 3 on the opposite side front suspension.
  3. Verify repair.

 

Replace Lower Arm Bushing (For Vehicle Type A, B and C)

  1. Remove the front lower arm (both sides) according to MS3 online instructions or the Workshop Manual (section 02-13 FRONT LOWER ARM REMOVAL/INSTALLATION).
  2. Remove the front lower arm bushing using the SSTs or bushing adapters.

Set SSTs (49 G030 797 and 49 B025 004) and the front lower arm on a shop press as shown in the figure and remove the front lower arm bushing.

Set SSTs (49 G030 797 and 49 B025 004)

  1. Install the front lower arm bushing (D) using SSTs.

Install the front lower arm bushing so that the projection (A) shown in the figure is pointing toward the front (B) and out of the vehicle (C).

NOTE:

  • Before installing the new bushing, wipe the inside of the outer tube and make sure it is clean.
  • Apply soap suds to the front lower arm bushing to facilitate installation.
  • If soap suds gets in the inner pipe of the front lower arm bushing, always wipe it off using a cloth.

 

Set SSTs (49 G030 797 and 49 B025 004) projection (A)

 

CAUTION: Make sure that the bushing has been properly inserted by checking that the tab of the bushing is completely expanded as shown in the OK illustration.

OK NG
Tab is completely expanded Tab is NOT completely expanded yet
Tab is completely expanded Tab is NOT completely expanded yet

 

  1. After the installation, verify that the front lower arm bushing has been installed to the correct position by the procedure shown in the figure.

Specification: Width: 5.8 +/- 0.8mm (0.22 +/- 0.03 in)

Measure the distance of the lower arm end face (A) and the inner pipe bushing (B). Measure the width as shown
Measure the distance of the lower arm end face (A) and the inner pipe bushing (B). Measure the width as shown

 

  1. Install the front lower arm (both sides) according to MS3 online instructions or the Workshop Manual (section 02-13).

NOTE: For the joint sections with rubber bushings, raise the vehicle using a lift, and then temporarily tighten the installation bolts and nuts. Lower the vehicle to the ground and tighten them to the specified tightening torque.

  1. Inspect the wheel alignment and adjust if necessary.
  2. Verify repair.

 

PART(S) INFORMATION

Description Qty. Notes Part Number
Front Strut Bearing 1 or 2 Type A only KR27-34-38X
Piston Rod Nut 2 All

Non-reuseable nut  R

9YB0-41-237
Protector 2 Type A , B and E KDY5-34-081
Bump Stopper 2 Mazda6 only GHY9-34-111
F. Lower Arm Rubber Bushing 2 Type A, B and C

KDY5-34-470A can also be used

KD35-34-470C

 

WARRANTY INFORMATION

NOTE:

  • This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair.
  • This repair will be covered under Mazda’s New Vehicle Limited Warranty term.
  • Additional diagnostic time cannot be claimed for this repair.
  • Type A, B and C repairs have two different causal parts (front shock absorber and lower arm). Submit two separate claims.

Front Shock Absorber Repair (All Types)

CX-5, Mazda6 CX-5, Mazda6 CX-3
Warranty Type A A A
Symptom Code 82 82 82
Damage Code 9A 9A 97
Part Number Main Cause KR27-34-38X KR27-34-38X 7777-SP-K08
Quantity 0, 1 or 2 0, 1 or 2 0
Operation Number / Labor Hours With front lower arm bushing replacement Without front lower arm bushing replacement XXL9PBRX / 0.9 Hrs.
XXK8NDRX / 0.6 Hrs. XXKBKXRX / 0.9 Hrs.

 

Front Lower Arm Repair (Type A, B and C)

CX-5, Mazda6
Warranty Type A
Symptom Code 82
Damage Code 93
Part Number Main Cause KD35-34-470C or KDY5-34-470A
Quantity 2
Sublet Code If Wheel Alignment Check and Adjust was performed outside of shop, claim the actual invoice amount with the sublet code “Z9”.
Operation Number / Labor Hours Replace both lower arm bushings Select one applicable repair below
1.  Wheel Alignment Check & Adjust was performed outside of shop.

XXK8NARX, 0.8Hrs.

2.  Wheel Alignment Check & Adjust was performed at dealer using 4-wheel alignment tester XXK8NBRX, 1.8Hrs.

3.  Wheel Alignment Check & Adjust was performed at dealer using 4-wheel alignment tester with Wireless Type.

XXK8NCRX, 1.4Hrs.

 


02-010/16

07/21/2016

https://www.nhtsa.gov/recalls?nhtsaId=10091901

https://www.nhtsa.gov/recalls?nhtsaId=10085444

https://static.nhtsa.gov/odi/tsbs/2016/SB-10085444-6903.pdf

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02-010/16

04/05/2016

https://www.nhtsa.gov/recalls?nhtsaId=10093123

https://static.nhtsa.gov/odi/tsbs/2016/SB-10093123-6903.pdf

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02-010/16

03/10/2016

https://www.nhtsa.gov/recalls?nhtsaId=10101081

https://www.nhtsa.gov/recalls?nhtsaId=10090821

https://static.nhtsa.gov/odi/tsbs/2016/SB-10090821-6903.pdf

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02-003/15

12/17/2015

https://www.nhtsa.gov/recalls?nhtsaId=10105646

https://static.nhtsa.gov/odi/tsbs/2015/SB-10105646-2532.pdf

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02-003/15

02/04/2015

https://www.nhtsa.gov/recalls?nhtsaId=10100735

https://static.nhtsa.gov/odi/tsbs/2015/SB-10100735-2532.pdf

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4 thoughts on “Knocking Squeaking Noise from Front Shock Absorber, Creaking Noise From Front Lower Arm Bushing – 2013-2016 Mazda”

  1. I have a cx3 2017 model dynamic 2,0litre auto, also have a bad noise on front left shock absorber when taking any bumps on the road, vehicle was just back from service and both sides coil protectors where installed but the noise is bad now on left front side, booked in to dealer Barloworld PMB next week, will see what happens??

    Reply
  2. This has also been an issue with my mazda3 as well as creaking straining noises from my accelerator and knocking while breaking

    Reply
  3. GOOD MORNING SIRS,

    REGARDING TO YOUR REPORT “Knocking Squeaking Noise From Front – 2013-2016 Mazda”, I HAVE A MAZDA CX5 ASSEMBLED 2015 / MODEL 2016 AND I ALSO DETECTED THE KNOCKING NOISE IN THE FRONT SHOCK ABSORVER, SPECIALLY WHEN I CROSS OVER SPEED BUMP. I WOULD LIKE TO KNOW WHAT FIXES SHOULD BE DONE TO MY VEHICLE TO ASK MY DEALER. MY VEHICLE VIN NUMBER: JM8KE4W77G0352509.

    I WOULD APPRECIATE YOUR SUPPORT. THANKS IN ADVANCE.

    MARCEL SANTOS

    Reply

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