Disclaimer***Acura TSX V6-3.5L Technical Service Bulletin # 12-041 Date 130308
Suspension - Front End Clunk in Hot Weather
12-041
March 8, 2013
Applies To
2009-13 TL - ALL
2009-13 TSX-ALL
Front Suspension Clunk in Hot Weather
(Supersedes 12-041, dated February 28, 2013, to revise the information marked by the black bars or asterisks)
REVISION SUMMARY
Under POSSIBLE CAUSE, CORRECTIVE ACTION, PARTS INFORMATION, WARRANTY CLAIM INFORMATION, and REPAIR
PROCEDURE, information was changed. Under Applies To, 2013 models were 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
Hot weather causes the grease to pool on the bottom of the ball joint, causing a knocking noise.
CORRECTIVE ACTION
Replace both of the front lower ball joints with the service parts made to address this specific symptom. If the lower ball joints were previously
replaced, then replace both front knuckle assemblies with those listed in this bulletin.
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PARTS INFORMATION
TOOL INFORMATION
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WARRANTY CLAIM INFORMATION
The normal warranty applies.
DIAGNOSIS
Raise the vehicle on a lift high enough to let the suspension hang. Lower the vehicle, then test-drive it and listen for a clunking noise.
^ 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.
2. Remove the wheel nuts and the front wheel.
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 with ones listed in this bulletin.
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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.
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.
5. Remove the brake hose bracket mounting bolt from the knuckle.
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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.
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.
8. Remove the front brake disc.
^ Remove the brake disc 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
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bolt 90 at a time to prevent the brake disc from binding.
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.
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
^ TL model - during reassembly, use a new castle nut and 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.
^ TSX model - during reassembly re-use the castle nut and insert a new cotter pin to 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.
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.
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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.
14. Disconnect the upper arm ball joint from the knuckle using the ball joint thread protector and the ball joint remover.
15. Pull the knuckle outward, and separate the outboard joint from the front hub using a soft face hammer outward.
^ If replacing the knuckle assembly, remove it.
^ If using 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.
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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 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.
17. Separate the hub from the old knuckle using the hub disassembly 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.
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18. Press out the wheel bearing inner race of the hub using the hub disassembly pin, a commercially available bearing separator, and a hydraulic
press.
19. Remove the snap ring and the splash guard from the knuckle.
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.
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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.
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.
23. Install a new snap ring securely in the knuckle.
24. Install the splash guard, and tighten the screws to the specified torque, then remove the knuckle assembly from the vise.
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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.
26. Install the new knuckle assembly, then go to step 35.
27. Remove the boot clip, then remove the boot off the ball joint, and wipe the grease off the exposed portion.
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-Be) 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.
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29. Position the ball joint tool kit, the adapter G, and the C-frame 0TC7248 (commercially available) on to the knuckle ball joint.
NOTE
Make sure the attachments are installed securely.
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 ball joint into the knuckle.
NOTE
Confirm that the new lower ball joint is stamped with a letter P, indicating a part to resolve clunk noise in hot weather.
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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.
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.
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36. Check the wheel alignment, and adjust it if necessary.
