Thumping Noise from Under Front – 2013-2015 Mazda

MULTI-MODEL – UNUSUAL NOISE WHEN STARTING TO MOVE VEHICLE WHILE STEERING WHEEL IS TURNED TO FULL LEFT POSITION

APPLICABLE MODEL(S)/VINS

2014-2015 Mazda3 vehicles with VINs lower than JM1BM******233957 (produced Sept. 22, 2014)

2014-2015 Mazda6 vehicles with VINs lower than JM1GJ******210201 (produced Sept. 22, 2014)

2013-2015 CX-5 vehicles with VINs lower than JM3KE******531471 (produced Sept. 22, 2014)

 

Unusual thumping noise from under the front of the vehicle.

This noise only occurs when starting to move the vehicle while the steering wheel is turned to the full left position.

 

NOTE: The noise will not occur if the steering wheel is in the center or full right position.

The noise is caused when the edge of the left side inner ball joint gets stuck with the steering gear housing.

To eliminate the noise, the shape of the inner ball joint edge has been changed.

 

REPAIR PROCEDURE

1. Verify the concern by turning the steering wheel full left, then start moving the vehicle.
   • If the noise is not present, this service information does not apply.
   • If the noise is present, replace the driver’s-side tie rod assembly with a modified part.
2. Remove the left front lower control arm (A) according to the on-line instructions on MS3 or the Workshop Manual (section 02-13).

3. Remove the driver’s side (A) tie-rod end (B) boot band and (C) boot from the steering rack.

CAUTION: Using shop air, blow the surrounding area clean before removing the boot to prevent dust and debris from adhering to the steering gear.

4. Insert a flathead screwdriver into the boot band (as shown below), then press the caulked area outward to remove the boot band.

5. Remove the boot from the steering gear.
6. Lock the steering gear end (pinion gear side) with a suitable wrench to prevent rotation.

 

NOTE: The steering gear is shown below removed from the vehicle for illustrative purposes only. It is not necessary to remove the steering gear from the vehicle.

7. Remove the tie-rod.
8. Install a modified tie rod assembly to the steering gear.

Tightening Torque: 70 – 95 Nm {52 – 70 ft. lbf., 9.6 – 13 kgfm}

9. Squeeze approx. 1cc of grease out of the tube onto your finger.

10. Apply the grease all the way around the inner ball joint edge (as shown below).

11. Reinstall the boot using a new boot band.

NOTE: Tighten the boot band until the clearance between the ends of the band are 2-4 mm (as shown below).

12. Reinstall parts in the reverse order of removal.

 

PART(S) INFORMATION

Part Number	Description	Qty.	Notes
GHY2-32-24X	Inner Ball Joint Assy.	1	Mazda3 / Mazda6
KDY1-32-24X	Inner Ball Joint Assy.	1	CX-5
BHY1-32-GR1	Grease	1	One (1) tube repairs twenty (20) vehicles

 

NOTE:

• GHY2-32-24X / KDY1-32-24X: includes inner ball Joint, wire clamp and snap pin.

 

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