SUBJECT: Popping/Creaking Noise in Front Suspension
NO: 02-01 -98
GROUP: Front Suspension
DATE: Mar. 27, 1998 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-02-97 REV. A DATED DECEMBER 15, 1997 WHICH SHOULD BE NOTED IN THE 1997 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). THE RIGHT MOTOR MOUNT SHOULD NOT BE REPLACED ON VEHICLES BUILT AFTER MAY 12, 1997. THE REPAIR TABLE HAS BEEN UPDATED. THE ADDITIONS ARE HIGHLIGHTED WITH ASTERISKS.
MODELS: 1995 - 1998 (PL) Neon
SYMPTOM/CONDITION:

A popping noise from the front suspension may be experienced while

  • Going in reverse or forward with the steering wheel turned completely in one direction (parking lot maneuvers)
  • Shifting from drive to reverse, reverse to drive, etc.
  • Pulling in/out of driveway
  • Large dips/bumps in the road such as speed bumps
DIAGNOSIS: If the customer describes the front suspension noise in conditions such as those described above, perform the Repair Procedure
PARTS REQUIRED:
NOTE: THE 1995 NEONS BUILT IN 1994 USED 13" KNUCKLE ASSEMBLIES WITH 13" OR 14" WHEELS. LATER BUILT VEHICLES HAVE 13" OR 14" KNUCKLE ASSEMBLIES TO MATCH ORIGINAL WHEEL SIZE. TO DETERMINE THE PROPER KNUCKLE SIZE, COUNT THE STUDS ON THE HUB THEN REFER TO THE PARTS LIST PROVIDED.
1   04897662AA   Assembly, 14" Steering Knuckle/Bearing (Right Front) (5 Stud Hub)
1   04897663AA   Assembly, 14" Steering Knuckle/Bearing (Left Front) (5 Stud Hub)
1   04897928AA   Assembly, 13" Steering Knuckle/Bearing (Right Front) (4 Stud Hub)
1   04897929AA   Assembly, 13" Steering Knuckle/Bearing (Left Front) (4 Stud Hub)
2   04626100AB   Mount, Upper Strut
6   06101448   Nut, Upper Strut Mount
1   04668200   Mount, Engine Right
1   04318070   Silicone spray (Right Engine Mount)
1   04318064   Lube, Driveshaft (Wheel Bearing Grease   (MS-5646)


CAUTION: DO NOT USE THE WHEEL SIZE TO DETERMINE PROPER KNUCKLE PART NUMBERS.
REPAIR PROCEDURE:
This bulletin involves inspecting/replacing as needed both front wheel bearings and steering knuckles, front upper strut mounts, engine mounts, and lubing the drive shafts.

NOTE: USE TABLE TO DETERMINE WHICH STEPS TO PERFORM BASED ON VEHICLE BUILD DATE AND IF TECHNICAL SERVICE BULLETIN 02-02-97, DATED FEBRUARY 28, 1997 HAS BEEN PERFORMED.
BUILD DATE   PERFORM STEPS:
Before MAY 12, 1997   (MDH 05-12-XX) TSB 02-02-97not completed   1 -8
Before MAY 12, 1997   (MDH 05-12-XX) TSB 02-02-97completed 6-8
Between May 12, 1997 (MDH 05-12-XX) &August 29,1997 (MDH 08-29-XX)   **6 and 8only**
After August 29 1997 (MDH 08-29-XX)   **8**


NOTE: ALL FRONT KNUCKLE/BEARING/HUB REPAIR PROCEDURES FOR STEPS 1THROUGH 5, CAN BE FOUND IN THE 1998 NEON SERVICE MANUAL(PUBLICATION NUMBER 81-270-8025) GROUP 2 (SUSPENSION).

  1. Remove both left and right front knuckle/bearing/hub assemblies.
  2. Press the hub out of the old knuckle/bearing/hub assemblies.
  3. Press the old hubs into the new knuckle/bearing assemblies.
  4. Before the knuckle/bearing/hub assemblies are installed on the vehicle, put a small amount of grease (Wheel Bearing Lube- p/n 04318064) on the entire face of the driveshaft that makes contact with the hub bearing assembly (Figure 1).
  5. Install both left and right front knuckle/bearing/hub assemblies.
  6. Replace the upper strut mount by following the procedures in the 1998 Neon Service Manual (Publication No. 81-270-8025), Removal/installation, pages 2-16 to 2-17, and Assembly/Disassembly procedures 1 through 5 on pages 2-30 to 2-31 (Figure 2). The torque for the new upper strut mount nuts is 61 Nm (45 ft.lbs.).
  7. Remove the right engine mount as outlined in the 1998 Neon Service Manual(Publication No. 81-270-8025) (SOHC - pg. 9-18)(DOHC - pg. 9-64). Before installing the right engine mount, squirt enough grease (Silicone Spray - p/n 04318070) on to the engine mount (Figure 3) to provide proper lubrication between the mount and the bracket. Complete the installation procedure provided in the Neon Service Manual.**

    NOTE: IF THE SILICONE SPRAY (P/N 04318070) IS NOT AVAILABLE, ANOTHER SILICONE SPRAY MAY BE USED. HOWEVER THE SUBSTITUTE SILICON' SPRAY MUST NOT BE PETROLEUM BASED.
  8. Inspect and tighten remaining suspension components to specification; repair or replace as needed.
POLICY: Reimbursable within the provisions of the warranty.