A12-082

Service Bulletin
Applies To:
12-082
September 17, 2013
2008–12 Accord – ALL
2010–13 Crosstour – ALL
Front Suspension Clunk in Hot Weather
(Supersedes 12-082, dated June 4, 2013, to revise the information marked by the black bars)
REVISION SUMMARY
In Applies To, 2013 Crosstour was added.
SYMPTOM
A clunk is heard in the front suspension while driving
over irregular surfaces and in hot weather. The noise
goes away temporarily when the vehicle is lifted in the
air (the suspension is allowed to hang) and then
returned to the ground.
POSSIBLE CAUSE
High ambient temperatures cause the grease to
redistribute to the bottom of the ball joint, resulting in a
stick-slip knock.
CORRECTIVE ACTION
Replace both of the front lower ball joints with updated
service parts made to address this specific symptom. If
the ball joints were previously replaced, then replace
both front knuckle assemblies.
Crosstour Parts Description
Part Number
Knuckle Assembly, Left
(only if prior ball joint replaced)
51215-TP6-Y00
1
Knuckle Assembly, Right
(only if prior ball joint replaced)
51210-TP6-Y00
1
TOOL INFORMATION
Tool Description
Part Number
Adapter G
07XAF-001050A
07XAF-00105B
Ball Joint Remover, 28 mm
Ball Joint Thread Protector
10 mm
Ball Joint Thread Protector
12 mm
Ball Joint Thread Protector
14 mm
Ball Joint Tool Kit
PARTS INFORMATION
Accord/ Crosstour
Parts Description
Part Number
Lower Ball Joint
51220-TA0-306
QTY
2
Ball Joint Cotter Pin
94201-30220
2
Spindle Nut
90305-S3V-A11
2
Tie Rod Cotter Pin
94201-30220
2
Snap Ring
(if knuckle replaced)
90681-SJK-000
1
Upper Arm Ball Joint Cotter Pin
(if knuckle replaced)
94201-20220
2
Wheel Bearing
(if knuckle replaced)
44300-TA0-A61
2
Accord Parts Description
Part Number
Knuckle Assembly, Left
(only if prior ball joint replaced)
51215-TA0-Y60
1
Knuckle Assembly, Right
(only if prior ball joint replaced)
51210-TA0-Y60
1
 2013 American Honda Motor Co., Inc. – All Rights Reserved
QTY
QTY
Bearing Driver Attachment
C-Frame
Driver Handle
Oil Seal Driver Attachment
96 mm
Hub Assembly/
Disassembly Pin, 42 mm
Support Base
ATB 48394-50339 REV2 (1309)
07MAC-SL0A202
07AAF-SECA120
07AFF-SDAA100
07AAE-SJAA100
07AAF-TL2A150
(contains the following
parts)
07AAF-TL2A100
07AAF-TL2A200
07AAF-TL2A300A
07AAF-TL2A300B
07AAF-TL2A400
07746-0010600
OTC7248
(or commercially
available)
07749-0010000
07ZAD-PNAA100
07GAF-SD4A100
07965-SD90100
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CUSTOMER INFORMATION: The information in this bulletin is intended for use only by skilled technicians who have the proper tools, equipment,
and training to correctly and safely maintain your vehicle. These procedures should not be attempted by “do-it-yourselfers,” and you should not assume
this bulletin applies to your vehicle, or that your vehicle has the condition described. To determine whether this information applies, contact an
authorized Honda automobile dealer.
WARRANTY CLAIM INFORMATION
The normal warranty applies.
*Only one of the following repairs below will apply.
OP#
Description
4151A9
A
Replace both front knuckles.
2.3
Alignment – add
0.4
OP#
Description
4161C0
A
FRT
FRT
Replace both front ball joints.
1.5
Alignment – add
0.4
Failed Part:
P/N 51220-TA0-A02
Defect Code:
07409
Symptom Code:
04201
Skill Level:
Repair Technician
DIAGNOSIS
Raise the vehicle on a lift high enough to let the
suspension hang. Lower the vehicle, then test-drive it
to confirm the clunking noise is gone.
• If the noise is gone, go to REPAIR PROCEDURE.
• If the noise is still there, this bulletin does not apply.
Continue with normal troubleshooting.
REPAIR PROCEDURE
1. Raise and support the vehicle.
NOTE: Do this repair to both sides of the front
suspension.
3. Clean the top surface of both lower ball joints in the
front knuckles and inspect for a paint mark,
indicating prior replacement.
• If there is a paint mark, replace both front knuckle
assemblies.
NOTE: Ball joints can only be replaced one time
on a knuckle and then it requires replacement.
• If there is no paint mark, replace both lower ball
joints.
LOWER BALL JOINT
PAINT MARK
4. Remove the wheel speed sensor and its harness
brackets at the knuckle assembly and at the
damper assembly. Do not disconnect the wheel
speed sensor connector.
• If using the existing knuckle assemblies, go to
step 7.
• If replacing knuckle assemblies, go to step 5.
2. Remove the wheel nuts and the front wheel.
WHEEL NUTS
108 N.m (80 lb-ft)
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5. Remove the brake hose bracket mounting bolt from
the knuckle.
7. Pry up the stake on the spindle nut, then remove
the nut.
• If replacing the knuckle assemblies, go to step 8.
• If using existing knuckle assemblies, go to
step 9.
SPINDLE NUT
329 N.m
(242 lb-ft)
Replace.
STAKE
6. Remove the brake caliper bracket mounting bolts,
then remove the caliper assembly from the knuckle.
To prevent damage to the caliper assembly or the
brake hose, use a short piece of wire to hang the
caliper assembly from the undercarriage. Do not
twist the brake hose excessively.
CALIPER
ASSEMBLY
BRAKE CALIPER
MOUNTING BOLT
Accord - 108 N.m (80 lb-ft)
Crosstour - 137 N.m (101 lb-ft)
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8. Remove the front brake disc.
• Remove the brake flathead screws.
• Remove the brake disc from the front hub.
• Check the front hub for damage and cracks.
NOTE: If the brake disc is stuck to the front hub,
thread two 8 x 1.25 mm bolts into the brake disc to
push it away from the front hub. Turn each bolt 90°
at a time to prevent the brake disc from binding.
BRAKE
DISC
FLATHEAD SCREWS (4)
9.8 N.m (7.2 lb-ft)
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9. Remove the cotter pin from the tie-rod end ball
joint, then remove the nut.
NOTE: During installation, install a new cotter pin
after tightening the nut, and bend its end as shown.
07AAF-SDAA100
BALL JOINT THREAD
PROTECTOR
07MAC-SL0A202
BALL JOINT
REMOVER
TIE-ROD END
BALL JOINT NUT
54 N.m (40 lb-ft)
COTTER PIN
12. Disconnect the knuckle ball joint from the lower arm
using the ball joint thread protector and ball joint
remover.
NOTE: Do not force or hammer on the lower arm or
pry between the lower arm and the knuckle.
• If replacing the knuckle assemblies, go to
step 13.
• If using existing knuckle assemblies, go to
step 15.
13. Remove the cotter pin from the upper arm ball joint,
then remove the castle nut.
NOTE: During reassembly, install a new cotter pin
into the ball joint pin hole from the front to the rear
of the vehicle, and bend its end as shown. Check
the ball joint pin hole direction before connecting
the ball joint.
07AAF-SECA120
BALL JOINT THREAD
PROTECTOR
07MAC-SL0A202
BALL JOINT
REMOVER
Replace.
10. Disconnect the tie-rod end ball joint from the
knuckle using the ball joint thread protector and the
ball joint remover.
11. Remove the cotter pin from the knuckle ball joint,
then remove the castle nut.
NOTE: During reassembly, insert a new cotter pin
into the ball joint pin hole from the front to the rear
of the vehicle, and bend its end as shown. Check
the ball joint pin hole direction before connecting
the ball joint.
07MAC-SL0A202
BALL JOINT
REMOVER
CASTLE NUT
44 – 52 N.m
(33 – 38 lb-ft)
FRONT
07AAE-SJAA100
BALL JOINT THREAD
PROTECTOR
COTTER PIN
Replace.
FRONT
14. Disconnect the upper arm ball joint from the
knuckle using the ball joint thread protector and the
ball joint remover.
FRONT
CASTLE NUT
78 – 88 N.m
(58 – 65 lb-ft)
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COTTER PIN
Replace.
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15. Pull the knuckle outward and separate the outboard
joint from the front hub using a soft face hammer.
• If replacing the knuckle assembly, remove it.
• If using the existing knuckle assembly, move it
aside.
NOTE: Do not pull the driveshaft end outward. The
driveshaft inboard joint may come apart. During
installation, apply grease to the mating surfaces of
the wheel bearing and the driveshaft outboard joint.
KNUCKLE
16. Remove the front knuckle ring from the knuckle.
Inspect it for deformation and damage, and replace
it if needed.
• If replacing the knuckle assemblies, put the old
knuckle assembly in a vice to remove the front
knuckle ring. Remove the knuckle from the vice
once the ring is removed, then go to step 17.
• If using the existing knuckle assemblies, go to
step 27.
NOTE: When installing the front knuckle ring,
position the knuckle ring notch portion toward the
cutout near the ball joint in the knuckle, and align
the center of the knuckle ring ledge portion with the
center of the wheel speed sensor hole on the
knuckle.
Removal:
FRONT
KNUCKLE RING
OUTBOARD JOINT
KNUCKLE
RING LEDGE
KNUCKLE
RING
Installation:
KNUCKLE
RING NOTCH
KNUCKLE
CUT OUT
0o +- 5o
WHEEL SPEED
SENSOR HOLE
KNUCKLE RING LEDGE
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17. Separate the hub from the old knuckle using the
hub dis/assembly pin and a hydraulic press. Hold
the knuckle with the hydraulic press attachment or
equivalent tool. Be careful not to damage or deform
the splash guard. Hold onto the hub to keep it from
falling when pressed clear.
OLD KNUCKLE
Press
07GAF-SD4A100
HUB
DIS/ASSEMBLY
PIN
19. Remove the snap ring and the splash guard from
the knuckle.
SPLASH GUARD
KNUCKLE
SNAP RING
Replace.
SPLASH GUARD
SCREWS (3)
SPLASH
GUARD
9.8 N.m (7.2 lb-ft)
20. Press the wheel bearing out of the knuckle using
the driver handle, the attachment, and a press.
NOTE: This old wheel bearing will be used to assist
in the installation of the new wheel bearing into the
new knuckle assembly.
HYDRAULIC
PRESS
ATTACHMENT
HUB
18. Press out the wheel bearing inner race of the hub
using the hub dis/assembly pin, a commercially
available bearing separator, and a hydraulic press.
Press
WHEEL BEARING
INNER RACE
Press
OLD KNUCKLE
07749-0010000
DRIVER HANDLE
07746-0010600
ATTACHMENT
07GAF-SD4A100
HUB DIS/ASSEMBLY PIN
BEARING
SEPARATOR
OLD WHEEL BEARING
HYDRAULIC
PRESS
ATTACHMENT
HUB
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12-082
21. Press a new wheel bearing into the new knuckle
using the old bearing, a steel plate, the attachment,
the support base, and a press.
NOTE:
• Install the new wheel bearing with the wheel
speed sensor magnetic encoder (brown color),
toward the inside of the knuckle.
• Remove any oil, grease, dust, metal debris, and
other foreign material from the magnetic encoder
surface.
• Keep any magnetic tools away from the magnetic
encoder surface.
• Be careful not to damage the magnetic encoder
surface when you insert the new wheel bearing.
STEEL
PLATE
23. Install the splash ring and the splash guard.
24. Install the splash guard, and tighten the screws to
the specified torque, then remove the knuckle
assembly from the vise.
SPLASH GUARD
KNUCKLE
SNAP RING
Replace.
Press
OLD
WHEEL
BEARING
SPLASH GUARD
SCREWS (3)
9.8 N.m (7.2 lb-ft)
NEW
WHEEL
BEARING
INSIDE
SPEED
SENSOR
MAGNETIC
ENCODER
25. Install the hub onto the new knuckle assembly
using the driver handle, the attachment, the support
base, and a hydraulic press. Be careful not to
damage the splash guard.
07ZAD-PNAA100
ATTACHMENT
NEW
KNUCKLE
Press
07965-SD90100
SUPPORT BASE
NEW KNUCKLE
22. Set the new knuckle assembly in a vice to hold it
securely and install the front knuckle ring:
NOTE: Inspect the front knuckle ring for damage or
deformation prior to installation, and replace it if
necessary.
Position the knuckle ring notch portion toward the
cut out near the ball joint in the knuckle, and align
the center of the knuckle, and align the center of
the knuckle ring ledge portion with the center of the
wheel speed sensor hole on the knuckle.
07749-0010000
DRIVER HANDLE
07746-0010600
ATTACHMENT
SPLASH
GUARD
OLD HUB
KNUCKLE
RING LEDGE
KNUCKLE
RING
07965-SD90100
SUPPORT BASE
KNUCKLE
RING NOTCH
KNUCKLE
CUT OUT
0o +- 5o
WHEEL SPEED
SENSOR HOLE
KNUCKLE RING LEDGE
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26. Install the new knuckle assembly, then go to
step 35.
27. Remove the boot clip, then remove the boot from
the ball joint, and wipe the grease off the exposed
portion.
29. Position the ball joint tool kit, the adapter G, and the
C-frame OTC7248 (commercially available) on to
the knuckle ball joint.
NOTE: Make sure the attachments are installed
securely.
KNUCKLE
ADAPTER G
07XAF-001050A
BOOT
CLIP
C-FRAME
BOOT
28. Clean and wipe off the hub center, then install the
attachments (07AAF-TL2A300-A and B) of the ball
joint tool kit through the hub center. Position the
projection of the attachment (07AAF-TL2A300-B)
toward the lower side of the knuckle. Tighten it into
place by hand.
NOTE: Make sure that the flat part of the
attachment is parallel to the top of the knuckle ball
joint.
ATTACHMENT
ATTACHMENT
07AAF-TL2A150
07AAF-TL2A150
(07AAF-TL2A300-B)
(07AAF-TL2A300-A)
FLAT PART OF
ATTACHMENT
KNUCKLE
BALL JOINT
ATTACHMENT
07AAF-TL2A150
(07AAF-TL2A400)
PRESSURE
BOLT
ATTACHMENT
07AAF-TL2A150
(07AAF-TL2A300-B)
30. Tighten the pressure bolt of the C-frame, and
remove the knuckle ball joint.
NOTE: When tightening the pressure bolt, secure
the knuckle and the outboard joint.
31. Remove the ball joint tool attachments
(07AAF-TL2A300-A and B) from the hub.
32. Set the new ball joint into the knuckle.
NOTE: Confirm that the new lower ball joint is
stamped with a P, indicating a part to resolve clunk
noise in high ambient temperature conditions.
The knuckle ball joint
is stamped with a “P”.
TOP OF
KNUCKLE
BALL JOINT
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TK09P
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33. Position the ball joint tool kit and the C-frame
OTC7248 (commercially available) to the ball joint.
Tighten the pressure bolt of the C-frame until the
knuckle ball joint shoulder is fully seated in the
knuckle.
NOTE: Make sure the attachments are installed
securely. When tightening the pressure bolt, make
sure the knuckle and the ball joint are properly
aligned.
34. Using a yellow oil-based paint marker, paint the top
of the knuckle lower ball joint.
NOTE: The paint mark is used to identify a knuckle
that has had prior ball joint replacement. Always
replace the knuckle as an assembly if the ball joint
to be replaced has a paint mark.
KNUCKLE
ATTACHMENT
07AAF-TL2A150
(07AAF-TL2A200)
LOWER BALL JOINT
PAINT MARK
KNUCKLE
BALL JOINT
C-FRAME
ATTACHMENT
07AAF-TL2A150
(07AAF-TL2A100)
PRESSURE
BOLT
35. Install the remaining parts in reverse order of
removal, and note these items:
• First, install all of the components, and lightly
tighten the bolts and the nuts, then raise the
suspension to load it with the vehicle’s weight
before fully tightening it to the specified torque.
Do not place the jack against the ball joint pin of
the knuckle.
• Be careful not to damage the ball joint boot when
connecting the knuckle.
• Before connecting the ball joint, degrease the
threaded section, the tapered portion of the ball
joint pin, and the ball joint connecting hole, the
threaded section, and the mating surfaces of the
castle nut.
• Torque the castle nut to the lower torque
specification, then tighten it only far enough to
align the slot with the ball joint pin hole. Do not
align the castle nut by loosening it.
• Use a new spindle nut on reassembly.
• Before installing the spindle nut, apply a small
amount of engine oil to the seating surface of the
nut. After tightening, use a drift to stake the
spindle nut shoulder against the driveshaft.
• Before installing the wheels, clean the mating
surfaces between the brake disc and the inside
of the wheel.
• If the knuckle hub assembly was replaced,
before installing the brake disc, clean the mating
surfaces between the front hub and the inside of
the brake disc.
36. Check the wheel alignment, and adjust it if
necessary.
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