TECHNICAL BULLETIN ISSUE '2' CHANGES ARE HIGHLIGHTED WITH GRAY BACKGROUND SECTION: 204. Front Suspension Knock Noise - Diagnostic Procedure

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1 TECHNICAL BULLETIN No: Date: 30 OCT 2008 CIRCULATE TO: Service Mgr Warranty Workshop Body Shop Parts X X X X ISSUE '2' CHANGES ARE HIGHLIGHTED WITH GRAY BACKGROUND SECTION: 204 Front Suspension Knock Noise - Diagnostic Procedure AFFECTED VEHICLE RANGE: LR3 (LA) VIN: 5A Onwards Model Year: Onwards Range Rover Sport (LS) VIN: 6A Onwards Model Year: Onwards CONDITION SUMMARY: Situation: When driving over rough roads there may be a knocking noise coming from the front suspension. This could be caused by a number of different issues. Action: Should a customer express the above concern, follow the Diagnostic Procedure outlined in this bulletin to assist in identifying the source. PARTS: As necessary TOOLS: Front Stabilizer Bar Bushing Tightening Tool Front Stabilizer Bar Bushing Tightening Tool WARRANTY: Normal warranty policy and procedures apply. DIAGNOSTIC PROCEDURE FRONT SUSPENSION GENERAL TORQUE CHECK NOTE: Suspension bushings and ball joints should be inspected in both the loaded (wheels on ground / ramp) and unloaded (wheels 'free'). NOTE: For current torque values, refer to Workshop Manual (GTR); lookup sequence is as follows: GTR Home > NAS > Model > Service Information > Model Year > Workshop Manual > 2: Chassis > 204: Suspension > : Front Suspension > Specifications NOTE: The majority of knocks can be heard at approximately 25 mph (40 kph) on rough roads or over single-wheel inputs / shock. NOTE: Nuts should be replaced every time clamps are removed. NOTE: The information in Technical Bulletins is intended for use by trained, professional Technicians with the knowledge, tools, and equipment required to do the job properly and safely. It informs these Technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by 'do-it-yourselfers'. If you are not a Retailer, do not assume that a condition described affects your vehicle. Contact an authorized Land Rover service facility to determine whether this bulletin applies to a specific vehicle Jaguar Land Rover North America, LLC Page 1 of 9

2 1. Verify torque of stabilizer bar upper and lower link nuts. (Figure 1). Figure 1 2. Verify torque of damper lower bolt / nut and bushing. (Figure 2) Figure 2 3. Verify torque of control lower arm ball joint nuts and steering gear tie rod end nuts. (Figure 3) Figure 3 Page 2 of 9

3 4. Verify torque of front differential cross member and undertray fixings. (Figure 4) Figure 4 5. Verify torque of front upper suspension arm forward and rear bushing nuts. (Figure 5) If torque-tightening is necessary, this must be carried out at the correct ride height to prevent pre-loading of bushings. Figure 5 Page 3 of 9

4 6. Verify torque of front lower suspension arm forward and rear bushing nuts. (Figure 6) If torque-tightening is necessary this must be carried out at the correct ride height to prevent pre-loading of bushings. Figure 6 7. On vehicles not fitted with Dynamic Response, verify torque of stabilizer bar clamp nuts. (Figure 7) Figure 7 8. On vehicles fitted with Dynamic Response, use special service tools and to verify front actuator clamp torque. (Figure 8) Figure 8 Page 4 of 9

5 9. Range Rover Sport only: verify torque of front and rear body mount damper bolts / nuts. (Figure 9) 10. Roadtest vehicle to verify any repairs performed. Figure 9 FRONT SUSPENSION COMPONENT INSPECTION: BALL JOINTS NOTE: To isolate the steering gear design clearance, Verify the right-hand linkage with the steering held against the right lock stop. Likewise, Verify the left-hand linkage with the steering held against the left lock stop. 1. With the aid of another person holding the steering wheel firmly against the lock stops, firmly grasp the road wheel and apply a rocking motion. Inspect for free play in the steering linkage. (Figure 9) If free play is detected, establish where the play is by compressing the boot. Feel for any play in the inner ball joint while continuing to rock the road wheel. Replace the steering gear tie-rod / ball joint if any free play is detected. Figure 9 Page 5 of 9

6 2. Inspect steering gear tie rod end for free play. (Figure 10) Replace if required. Figure Inspect stabilizer bar links for free play at both ends. (Figure 11) Replace if required. Figure 11 Page 6 of 9

7 NOTE: Global Technical Reference (GTR) lookup sequence is as follows: GTR Home > NAS > Model > Service Information > Workshop Manual > 1: General Information > : Jacking and Lifting 4. Raise vehicle so that front wheels are clear of ground/ramp to enable insertion of a suitable lever (i.e.: a 1220mm- [48in) long steel tube). NOTE: The assistance of a second technician is required for the following step. 5. Place a lever between the ground / ramp and the tire and lift the wheel assembly with the lever. (Figure 12) Inspect for ball joint free play / lift / looseness. If free play is evident, replace the ball joint. 6. Roadtest vehicle to verify any repairs performed. FRONT SUSPENSION COMPONENT INSPECTION: BUSHINGS 1. Inspect lower wishbone bushings for cracks or splits. (Figure 13) Replace if required. Figure 12 Figure 13 Page 7 of 9

8 2. Inspect stabilizer bar bushings for crack or splits. (Figure 14) Replace if required. (For vehicles with Dynamic Response, see 'Dynamic Response Vehicles Only (below). 3. Roadtest vehicle to verify any repairs performed. Figure 14 FRONT SUSPENSION COMPONENT INSPECTION: STEERING COLUMN Figure 15 NOTE: There is an acceptable amount of backlash in the steering system. If in doubt compare with another vehicle by grasping shaft and move up and down. 1. Verify the steering column bolt / nut torque. (Figure 15) NOTE: Refer to Technical Bulletin LTB00097NAS3 for further information regarding inspecting / repairing steering column noise issues. 2. Inspect steering column for free play by gently rocking the steering wheel side-to-side. (Figure 16) 3. If free play is evident: Remove the lower fascia scuttle Inspect intermediate shaft breakaway joint for free play. 4. If relative movement can be felt across this joint, replace the intermediate shaft. 5. If no relative movement can be felt across the intermediate shaft joint but relative movement is still evident, replace the lower shaft. 6. Roadtest vehicle to verify any repairs performed. Figure 16 Page 8 of 9

9 RANGE ROVER SPORT WITHOUT DYNAMIC RESPONSE ONLY (FIGURE 17) 1. Remove rear body mount dampers. 2. Road test vehicle to verify noise is eliminated / still evident. 3. If noise is eliminated, replace rear dampers. 4. If noise is still evident, install original rear dampers. 5. Remove front body mount dampers. 6. Road test vehicle to verify noise is eliminated / still evident. 7. If noise is eliminated, replace front dampers. 8. If noise is still evident, install original front dampers. RANGE ROVER SPORT WITH DYNAMIC RESPONSE ONLY (FIGURE 17) 1. Inspect associated pipe routings for: Inadvertent pipe to frame/body contact. Small stones or other debris which may be 'grounding' the pipes or valve block to the frame / body. Figure 17 NOTE: If VIN is prior to 7A996253, refer to Technical Bulletin LTB00029NAS2 to verify Dynamic Response System software. 2. Roadtest vehicle to verify any repairs performed. 3. Remove rear body mount dampers. 4. Road test vehicle to verify noise is eliminated / still evident. 5. If noise is eliminated, replace rear dampers. 6. If noise is still evident, install original rear dampers. 7. Remove front body mount dampers. 8. Road test vehicle to verify noise is eliminated / still evident. NOTE: It is not necessary to install front body mount dampers on vehicles with Dynamic Response. Rear body mounts must be installed. 9. If noise is eliminated, return vehicle to customer. NOTE: Nuts must be replaced every time clamps are removed. Ensure clamp and chassis faces are clean and flat; remove any weld splatter if required. 10. If knock is still evident, remove actuator clamps and replace both stabilizer bar bushings and nuts. 11. Tighten actuator clamps nuts to correct torque. (Use Special Service Tools and ). 12. If noise is still evident, gently rock the steering wheel from side-to-side once a second while driving at approximately 20mph (32kph). 13. If a 'thud' noise is evident, remove fuse 9 in the left-hand-side engine compartment fuse box and repeat step If the 'thud' noise is eliminated, refer to Technical Bulletin LS for further information. 15. Install fuse 9 in the left-hand-side engine compartment fuse box. ALL VEHICLES 1. If the noise is reduced but still evident and all previous checks described are verified, contact the Land Rover Technical HelpLine for additional support. Page 9 of 9

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