Rattle, Pop or Click from Front End of Vehicle Over Rough Road Surfaces. Saturn Saturn 1995

For 1990-2009 cars

# Rattle, Pop or Click from Front End of Vehicle Over Rough Road Surfaces

Subject: | Rattle, Pop or Click from Front End of Vehicle Over Rough Road Surfaces (Remove Paint Splashes, Drops or Runs from Top of Front Strut)

Models: | 1995 Saturns built before and including VIN SZ175189

### Condition

Some customers may comment about a rattle, pop or click noise coming from the front of the vehicle, while traveling over rough road surfaces. This noise may sound like a dash rattle from inside the vehicle.

### Cause

Paint splashes, drops or runs on the top of the front strut mount(s) may prevent full contact between the front strut top mount and the front strut tower (vehicle body). Failure of the front strut mount make to make full contact with the front strut tower may cause a rattle, pop or clicking noise.

### Correction

Verify that the rattle, pop or clicking noise comes from the front strut by opening hood bouncing front end of vehicle while listening at the front strut areas. If rattle, pop or click is heard coming from the front strut tower area, proceed to "Procedures' in this bulletin. If rattle, pop or clicking noise is not heard coming from the front strut tower areas, road test vehicle to locate source of noise and repair.

### Procedures

Caution: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE ADDITIONAL SUPPORT TO THE OPPOSITE END OF THE VEHICLE THAT COMPONENTS WILL BE REMOVED FROM.

1. Raise vehicle on hoist.
2. Remove road wheel.
3. Loosen two strut assembly-to-steering knuckle bolts and nuts.

Important: Do not remove two strut-to-steering knuckle-to-strut bolts and nuts at this time.

4. Remove and discard the three strut assembly mount-to-body attachment nuts.
5. Remove the two strut assembly-to-steering knuckle bolts and nuts, and discard nuts.

Notice: Before removing front strut assembly, place a rag over the CV joint seal to protect it from damage.

6. Remove front strut assembly from vehicle.
7. Using an appropriate tool such as a gasket scraper, razor blade scraper, etc., remove paint drops, runs, and/or splashes from top of the front strut mount.

Notice: Use new strut assembly mount-to body attachment nuts; torque retention of old nuts may not be sufficient.

8. Position front strut assembly mount-to-body attachment nuts and tighten.

Tighten
Torque: 29 N·m (21 lb ft)

Notice: Use new strut assembly-to-steering knuckle assembly nuts: torque retention of old nuts may not be sufficient.

9. Position strut assembly to steering knuckle and install strut assembly-to-steering knuckle bolts. Thread on new strut assembly-to-steering knuckle nuts and tighten.

Important: With strut assembly-to-steering knuckle bolts and installed, but not tightened, push bottom of strut assembly inward while tightening.

Tighten
Torque: 29 N·m(21 lb ft)

Important: With strut assembly-to-steering knuckle bolts and installed, but not tightened, push bottom of strut assembly inward while tightening.

Tighten
Torque: 200 N·m (148 lb ft)

Notice: Before installing road wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors and drums. Failure to do so can cause wheel lug nuts to loosen in service.

10. Position road wheel onto hub.
11. Install road wheel lug nuts and tighten in a crisscross pattern. Repeat tightening pattern to make sure torque is correct.

Tighten
Torque: 140 N·m (103 lb ft)

12. Perform vehicle wheel alignment. (Refer to "Wheel alignment' in the "Alignment, Wheels and Tires" section of the "1995 Chassis Service Manual.")

### Parts Requirements

21010436 Nuts -- Strut Assembly Mount-to-body (3 required per strut)

21010929 Nuts -- Strut Assembly-to-Steering Knuckle Assembly (2 required per strut)

### Claim Information:

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows:

Case Type | Description | Labor Operation Code | Time
--- | --- | --- | ---
VW | R Front Strut and Remove Paint Splashes, drops or Runs | T9681 | 0.6 hrs
IMPORTANT: For alignment times, refer to Operation E2020. When Claiming alignment, relate the alignment tot he repair.
Add: To R Both Front Struts, if Necessary