02-001-18-3013h

Technical
Service Bulletin
Mazda North American Operations
Irvine, CA 92618-2922
Subject:
POPPING AND/OR SQUEAKING NOISE FROM FRONT SHOCK
ABSORBER AND/OR CREAKING NOISE FROM FRONT LOWER ARM
BUSHING
Bulletin No.: 02-001/18
Last Issued: 01/05/2018
BULLETIN NOTES
This bulletin supersedes the previously issued bulletin(s) listed below. The changes are noted below in Red.
Previously Issued TSBs:
Date(s) Issued
02-005/17
03/16/16 and 01/13/17
02-001/16
10/10/16, 04/15/16, 02/23/16 and 01/08/16
02-004/15
05/12/15 and 04/24/15
APPLICABLE MODEL(S)/VINS
2014-2016 Mazda3 vehicles (Japan built and Mexico built) with VINs starting with JM1 and 3MZ
2017 Mazda3 vehicles (Japan built) with VINs lower than JM1BN******156769 (Produced before June 13,
2017)
2017-2018 Mazda3 vehicles (Mexico built) with VINs starting with 3MZ
DESCRIPTION
Some vehicles may exhibit one or more of the following noises from the front suspension.



A squeaking noise from the front shock absorber when turning the steering wheel at a vehicle
standstill caused by stick-slip between the front strut bearing and the coil spring.
A popping noise from the front shock absorber when passing over speed bumps caused by the
bump stopper contacting the strut bearing when the shock absorber is compressed.
A creaking noise from the lower arm when driving over road bumps at 20-40 km/h caused by stickslip of the front lower arm bushing. The noise occurs when the road surface is wet or after a car
washing, and becomes more noticeable as the speed bump gets higher.
To correct these problems, the following changes have been made.


For the squeaking and popping noise, the shape of the bump stopper has been modified and a
protector has been installed onto the coil spring.
For the creaking noise, the friction of the lower arm bushing has been reduced by adding a dry
coating.
Customers having this concern should have their vehicle repaired using the following repair procedure.
Page 1 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 02-001/18
Last Issued: 01/05/2018
REPAIR PROCEDURE
1. Verify the customer concern of noise coming from under the front of the vehicle when driving over speed
bumps and/or driving on a rough road and/or turning the steering wheel at a standstill.
2. If the noise has been confirmed, check the VIN and perform the appropriate repair procedure according
to the following tables.
Vehicle Spec
Vehicle Type A Vehicle Type B Vehicle Type C
JM1BM******** (2.5L with B45G-34-111) 100001 - 250356 250357 - 280997 280998 - 355940
JM1BM******** (2.0L with B45A-34-111) 100001 - 250356 250357 - 300898 300899 – 355940
JM1BN********
N/A
N/A
100001 – 156768
3MZBM********
100001 - 195510 195511 - 330142
N/A
3MZBN********
N/A
100001 - 999999
N/A
Repair to Perform by Vehicle Type Vehicle Type A Vehicle Type B Vehicle Type C
1. Install Protector onto Spring
Perform DO NOT Perform DO NOT Perform
2. Replace Bump Stopper
Perform
Perform
DO NOT Perform
3. Replace Lower Arm Bushing
Perform
Perform
Perform
Page 2 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 02-001/18
Last Issued: 01/05/2018
Protector Installation
3. Remove the spring according to MGSS online instructions or the Workshop Manual (section 02-13
FRONT SHOCK ABSORBER AND COIL SPRING DISASSEMBLY/ASSEMBLY).
4. Degrease 1.5 turns of the spring from the top.
5. Cut a thin strip of paper to 138 mm in length (or use a cloth type measuring tape).
6. Place the strip of paper (or cloth measuring tape) along the inner side of the coil spring starting at point
(A) and mark the spot on the spring where (B) is. (B) is the starting point for the protector installation.
7. Install the protector (A) onto the coil spring aligning the end (slant cut side) with the marking at spot (B).
NOTE: Install the protector so the gap (C) is evenly aligned around the outer edge of the coil spring.
Page 3 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 02-001/18
Last Issued: 01/05/2018
Bump Stopper Replacement
8. Replace the bump stopper with the modified one according to MGSS online instructions or the Workshop
Manual (section 02-13 FRONT SHOCK ABSORBER AND COIL SPRING DISASSEMBLY/ASSEMBLY).
NOTE:


Before removing the mounting rubber, mark its original position so it can be re-installed later to the
same position.
When replacing the bump stopper with a modified one, apply grease to upper side of the bump
stopper and to the inside of the bump stopper (on the surface that contacts the damper rod).
CAUTION: It is not necessary to adjust the front wheel alignment because the front shock absorber and
mounting rubber are not being replaced. However, make sure to install the mounting rubber to the original
position.
A Front Shock Absorber C Coil Spring
B Mounting Rubber D Bump Stopper
Page 4 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 02-001/18
Last Issued: 01/05/2018
Lower Arm Bushing Replacement
CAUTION: Installation of the modified lower arm bushing will affect the road noise and the riding comfort in
a negative way. Therefore, only use this modified part for a customer vehicle with consideration of these
adverse effects.
9. Remove the front lower control arms (both sides) according to the on-line instructions on MGSS or the
Workshop Manual (section 02-13 FRONT LOWER ARM REMOVAL/INSTALLATION).
10. Remove the front lower arm bushing using SSTs 49 G030 797 and 49 B025 004.
11. Place the SSTs on the front lower control arm as shown below, then press out the bushing.
Page 5 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 02-001/18
Last Issued: 01/05/2018
12. Install the modified bushing using the same SSTs.
NOTE:




Before installing the new bushing, wipe the inside of the outer tube and make sure it is clean.
Apply soap suds to the bushing to ease the installation.
Always wipe off soap suds from the front lower control arm and bushing with a cloth.
Install the bushing so the projection (A) is pointing toward the front of the vehicle.
CAUTION: Make sure the bushing has been properly inserted by verifying that the bushing tab IS FULLY
EXPANDED, as shown in the illustration to the left (A). The illustration to the right (B) shows an example of
a bushing tab that IS NOT FULLY EXPANDED.
Page 6 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 02-001/18
Last Issued: 01/05/2018
13. After installing the bushing, verify the distance between the front lower control arm (A) and front lower
control arm bushing inner pipe (B) equals 5.8 +/- 0.8mm as shown below.
14. Reinstall the front lower control arm according to the on-line instructions on MGSS or the Workshop
Manual (section 02-13 FRONT LOWER ARM REMOVAL/INSTALLATION).
NOTE: For the joint sections with rubber bushings, raise the vehicle using a lift, and then temporarily tighten
the installation bolts. Then raise the vehicle using a wheel alignment lift rack (A) or lower the vehicle to the
ground (to load the suspension). Use a torque wrench (B) to tighten the bolts (C) to the specified tightening
torque.
15. Perform wheel alignment inspection and adjust if necessary.
Page 7 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 02-001/18
Last Issued: 01/05/2018
PARTS INFORMATION
New Part
Number
B45A-34-111A
Old Part
Number
B45A-34-111
Description
Qty.
Stopper, Bump
2
B45G-34-111A
B45G-34-111
Stopper, Bump
KDY5-34-081
9YB0-41-237
TK48-34-470A
--KD35-34-470E
KDY5-34-470A
Protector
Piston Rod Nut
Front Lower Arm
Bushing
Notes
For Japan built 2.0L
B4YA-34-111 (Service Part) can also be
used.
2
For Japan built 2.5L
B4YG-34-111 (Service Part) can also be
used.
2
All models
2
All models
2
NOTE:


For Mexico-built vehicles that are originally equipped with the Bump Stopper (BJS7-34-111), use
B45A-34-111A for the repair.
For Mexico-built vehicles that are originally equipped with the Front Rubber Bushing (BSJ7-34470), use TK48-34-470A for repair.
WARRANTY INFORMATION
Since two different causal parts (front shock absorber and lower arm) are involved in this repair, please
submit the claim divided into the following two claims.
NOTE:



This warranty information applies only to verified customer complaints on vehicles eligible for
warranty repair.
This repair will be covered under Mazda’s New Vehicle Limited Warranty term.
Additional diagnostic time cannot be claimed for this repair.
Page 8 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.
Bulletin No.: 02-001/18
Last Issued: 01/05/2018
Front Shock Absorber


Vehicle Type A: Install Protector and Replace Bump Stopper
Vehicle Type B: Replace Bump Stopper
Warranty Type
Symptom Code
Damage Code
Part Number Main Cause
Quantity
Operation Number / Labor
Hours
Related Part and Quantity
A
82
97
B4YA-34-111, B4YG-34-111, B45A-34-111A or
B45G-34-111A
2
XXK8NFRX / 0.6 Hrs.
9YB0-41-237
KDY5-34-081
Piston Rod 2 Vehicle Type A
Nut
and B
Protector 2 Vehicle Type A
only
Front Lower Arm

Vehicle Type A, B and C: Replace Lower Arm Bushing
Warranty Type
Symptom Code
Damage Code
Part Number Main
Cause
Quantity
Operation Number /
Labor Hours
Sublet Code
Dealer Sublets Wheel
Alignment
A
82
93
TK48-34-470 (Lower Arm
Bushing)
2
XXK8NARX / 0.8 Hrs.
(Only replacement of front
lower arm bushing)
Z9
Dealer Performs Wheel Alignment
XXK8NBRX / 1.8 Hrs.
(Includes front wheel alignment check and adjust
using 4-wheel alignment tester)
---
Page 9 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.
© 2018 Mazda North American Operations, U.S.A.