4/15/2018 #PI0491: Clunking Noise Behind Left and/or Right Front Wheel When Driving - (Jun 14, 2011) 2006 Chevrolet Impala MotoLogic

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Caroline Lucas
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1 2006 Impala Subject: Clunking Noise Behind Left and/or Right Front Wheel When Driving Report a problem with this article Models: Chevrolet Impala Equipped with RPO 9C1 or 9C3 Police Package Condition/Concern Some customers may comment on a clunk type noise coming from under the front of the vehicle when driving and/or when putting the transmission in Drive or Reverse. The noise is usually described as coming from the front foot well area or from behind the left or right front wheel. This condition may be caused by the frame (cradle) mounting area of the vehicle underbody being damaged when the vehicle suspension bottoms out under full compression. Continued severe bottoming out of the vehicle may cause structural damage to the frame mounting points. If these mounting areas are damaged, the frame can shift when operating the vehicle causing the clunking noise. Important: A separate bulletin addresses the suspension bottoming concern. Refer to Corporate Bulletin Number Inspection/Insulator Revision Use the following steps to inspect the rear sub frame mounting area of the vehicle and to revise the insulator. 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 2. Support the rear of the frame (3) using tall screw type jackstands.

2 3. Remove the frame bolts from the rear of the frame. 4. Using the screw on the jackstand, lower the rear of the frame no more than 63 mm (2.5 in). 5. Remove the upper portion of the two rear insulators. Tip: It may be necessary to clean any surface rust or dirt from the area using a piece of 80 grit sandpaper. 6. Inspect the area around the left and right bolt hole for cracks in the metal engine mounting plates. If no cracks are found, proceed to step 7. If cracks are found, proceed to the repair section of this bulletin (Engine Mount Plate Replacement). 7. Apply an epoxy primer, as required, to the areas that were sanded in the inspection procedure.

8. On the upper insulators, grind off the raised dimples using a hand or bench grinder. Use care to remove only the dimple, not the surrounding metal. Apply an epoxy primer. 9.

3 8. On the upper insulators, grind off the raised dimples using a hand or bench grinder. Use care to remove only the dimple, not the surrounding metal. Apply an epoxy primer. 9. Reinstall the insulators onto the frame assembly. 10. Using the screw type jackstands, raise the frame into position. 11. Install the two frame bolts. Tighten Tighten the bolts to 160 Y (118 lb ft). 12. Remove the jackstands and lower the vehicle. Engine Mount Plate Replacement Note: Reinstall the two rear frame mounting bolts and tighten to 160 Y (118 lb ft) before performing the following steps. If cracks are found in the left and right engine mount plates, use the following steps to install new engine mount plates and cage nut plate assemblies (Reinforcement Assembly-Engine Mount Bracket) if required. Special Tools J Universal Engine Support Table 1. Install the engine support fixture to support the engine/transaxle assembly. Refer to Engine Support Fixture for the 3.5L engine, Engine Support Fixture for the 3.9L engine in SI.

4 2. Remove the two bolts attaching the brake master cylinder to the power brake booster and separate the components. 3. Remove the positive battery cable retainers. Position the positive battery cable aside. Refer to Battery Positive and Negative Cable Replacement in SI. 4. Remove the fasteners that mount the electronic brake control module (EBCM) to the body. 5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI. 6. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in SI. 7. Remove the lower radiator air deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement in SI. 8. Disconnect the power steering cooler pipe from the frame. Refer to Power Steering Cooler Pipe/Hose Replacement in SI. 9. Secure the power steering cooler to the exhaust pipe with a wire tie. 10. Remove the stabilizer shaft links. Rotate the stabilizer shaft up to gain access to the mounting bolts for the power steering gear. Refer to Stabilizer Shaft Link Replacement in SI. 11. Remove the mounting bolts for the power steering gear. Refer to Steering Gear Replacement in SI. 12. Secure the power steering gear to the catalytic converter using wire ties. 13. Remove the nuts that secure the engine mount to the frame. Refer to Engine Mount Replacement for the 3.5L engine, Engine Mount Replacement for the 3.9L engine in SI. 14. Remove the nuts that secure the transaxle mount to the frame. Refer to Transmission Mount Replacement - Left Side for the 4T65-E transaxle in SI. 15. Disconnect both front wheel speed sensor connectors (1), if equipped. 16. Remove both front wheel speed harness retainers (2) from the frame and the lower control arms, if equipped. 17. Separate both of the lower ball joints from the steering knuckle. Refer to Lower Control Arm Ball Joint Replacement in SI.

18. Lower the vehicle until the frame contacts the J-39580. 19.

21. Remove the frame reinforcements (2). 22.

5 18. Lower the vehicle until the frame contacts the J Remove the frame reinforcement nuts (3). 20. Remove the frame reinforcement bolts (1). 21. Remove the frame reinforcements (2). 22. Remove the bolts (1) that secure the frame to the body. 23. Raise the vehicle in order to separate the frame from the body. Remove the frame assembly.

24. Position and support the brake lines, ECBM and the master cylinder to allow access to the repair area. Use care to not damage the brake system components. 25.

These marks will be required to locate the replacement parts on the vehicle. Note: Note the number and location of the factory welds for installation of the service parts. 26.

6 24. Position and support the brake lines, ECBM and the master cylinder to allow access to the repair area. Use care to not damage the brake system components. 25. From the underside of the vehicle, using a sharp scribe, mark the location of the left and right engine mount plates, mark the frame rail location and the one bar locations. These marks will be required to locate the replacement parts on the vehicle. Note: Note the number and location of the factory welds for installation of the service parts. 26. Using a 10 mm (3/8 in) spot weld remover, locate and drill out the factory welds that attach the left and right engine mount plates to the frame rails. Use care to only drill through the plate. Do not damage the frame rails by drilling too deep. Also drill out the welds attaching the engine mount plates to the one bar assembly using an 8 mm (5/16 in) spot weld remover. 27. Remove the left and right engine mount plates.

7 28. Inspect the cross car reinforcement (one bar) for cracks around the bolt hole. If there are no cracks, proceed to the installation steps (#37). If the cracks around the bolt hole fall within the size (footprint) of the cage nut service plate, proceed with the next step. 29. Locate the four spot welds that attach the cage nut assembly to the one bar. Using an 8 mm (5/16 in) drill bit, remove the spot welds that attach the cage nut assembly and remove the cage and nut through the rectangular hole in the one bar. Perform this procedure on the left and right cage nut assemblies. 30. Drill an 8 mm (5/16 in) hole at the outer end of any metal cracks radiating from the mounting bolt hole in the one bar. This will terminate the cracks. 31. Remove any burrs or rough metal from the inside of the one bar where the cage nut service plates mount. 32. Prepare the plug weld mating surfaces, as necessary.

33. Insert the service cage nut plate, with the long side toward the center of the vehicle, through the rectangular hole in the one bar. Center the service part using the bolt hole. 34.

Install the service plate using MIG plug weld in the four holes drilled during the removal of the original cage nut assembly. 36.

8 33. Insert the service cage nut plate, with the long side toward the center of the vehicle, through the rectangular hole in the one bar. Center the service part using the bolt hole. 34. Clamp the service plate into position ensuring the plate covers all of the holes drilled in the one bar. 35. Install the service plate using MIG plug weld in the four holes drilled during the removal of the original cage nut assembly. 36. MIG plug weld, to the service plate, any previously drilled crack terminating holes. 37. On the left and right engine mounting plate service parts, drill 8 mm (5/16 in) plug weld holes in the locations noted from the original part. 38. Prepare the plug weld mating surfaces, as necessary. 39. Apply Weld-Thru Coating to the plug weld mating surfaces. 40. Clamp the engine mounting plated to the vehicle using the scribe marks created during removal for position reference. Ensure the plates are held securely to the one bar. If necessary use an appropriately sized bolt and washer in the cage nut to pull the service part tight to the one bar.

Reinstall the two bolts attaching the brake master cylinder to the power brake booster. Tighten Tighten the master cylinder mounting nuts to 33 Y (24 lb ft).

9 41. Weld the engine mount plates to the vehicle using MIG plug welds. 42. Coat the repair area with an epoxy primer as required. 43. Position the brake lines, reinstall the fasteners that mount the electronic brake control module (EBCM) to the body. Tighten Tighten the fasteners to 5 Y (44 lb in). 44. Reinstall the two bolts attaching the brake master cylinder to the power brake booster. Tighten Tighten the master cylinder mounting nuts to 33 Y (24 lb ft). Note: Ensure step 8 of the Inspection/Insulator Revision section of this bulletin is performed before the reinstallation steps. 45. Reinstall the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Removal and Installation Procedure in SI. 46. When reinstalling the drivetrain and front suspension frame, use the original rear frame mounting bolts. When tightened, these bolts will compress and settle the repair area of the vehicle. This may stretch the bolts. To ensure proper fastener performance, remove the two original rear bolts and install two new rear frame mounting bolts. Apply HIGH-TEMP, HIGH-STRENGTH THREADLOCKER GM P/N or the equivalent. Tighten the bolts to 160 Y (118 lb ft). Parts Information

10 Part Number Description Qty. Material Allowance Plate- Eng Mt Right Plate- Eng Mt Left NPN Reinforcement Assembly-Engine Mount Bracket Bolt-Drivetrain And Front Susp. Frame HIGH-TEMP, HIGH- STRENGTH THREADLOCKER Drill-Spot Weld Removal 2 2 As Req. 2 $50.00 NPN Paint and Material As Req. GD Warranty Information For vehicles repaired under warranty, use: Labor Operation Description Labor Time E9535* Inspect Rear Frame Mount Area, Revise Insulator 1.1 hrs Add Replace Lt. and Rt. Engine Mount Plates, Install Reinforcements 8.9 hrs * This is a unique labor operation for bulletin use only. It will not be published in the Labor Time Guide. GM bulletins are intended for use by professional technicians, NOT a "do-ityourselfer". They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information. WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION

# C: Information on Body Mount Bolt Stripped or Will Not Loosen - (Mar 22, 2013)

# C: Information on Body Mount Bolt Stripped or Will Not Loosen - (Mar 22, 2013) Page 1 of 7 Document ID: 3350409 #10-08-61-001C: Information on Body Mount Bolt Stripped or Will Not Loosen - (Mar 22, 2013) Subject: Information on Body Mount Bolt Stripped or Will Not Loosen Models: