Knocking Noise from Front Suspension – 2006-2007 Toyota RAV4

SU009-07

 

KNOCKING NOISE FROM FRONT SUSPENSION

 

Introduction

Some customers may experience a thump or knocking noise coming from the front of the vehicle when traveling over bumps. This TSB includes repair information and updated parts information to address the condition. Use the following repair procedure to remove and replace the front spring assembly and spring bumper.

 

Applicable Vehicles

2006 – 2007 model year RAV4 vehicles produced BEFORE the Production Change Effective VINs in this TSB.

 

Production Change Information

MODEL	PLANT	ENGINE	PRODUCTION CHANGE EFFECTIVE VIN
RAV4	Tahara	2AZ-FE	JTMBD3#V#75086433
			JTMZD3#V#75055796
		2GR-FE	JTMBK3#V#75025450
			JTMZK3#V#75010774
	Shokki	2AZ-FE	JTMBD3#V#76037809
			JTMZD3#V#76036303
		2GR-FE	JTMBK3#V#76017829
			JTMZK3#V#76006284

 

Parts Information

ENGINE	DRIVETRAIN	MODEL	PREVIOUS PART NUMBER	CURRENT PART NUMBER	PART NAME	QTY
2GR (V6)	2WD, 4WD	Sport Grade w/Steel Wheel or Base Grade w/Steel Wheel	48131-42510	48131-42520	Front Coil Spring	2
2AZ (4-Cyl)	2WD	Sport Grade, Limited Grade, or Base grade w/17-in. Wheel	48131-42570	48131-42580
	4WD	All Sport Models	48131-42580	48131-42550
—	—	All Models	48331-42030	48331-42050	Front Spring Bumper (RH, LH)	2
—	—		N/A	48334–42010	Plastic Sheet	2

 

Repair Procedure

1. Test drive the vehicle and confirm the condition.
2. Once the condition has been confirmed, remove both front struts.

Refer the Technical Information System (TIS), 2006 or 2007 model year RAV4 Repair Manual, Suspension – Front Suspension – “Suspension: Front Shock Absorber With Coil Spring: Removal”.

3. Once the strut assemblies have been removed from the vehicle, disassemble the strut assembly.

Refer to TIS, 2006 or 2007 model year RAV4 Repair Manual, Suspension – Front Suspension – “Suspension: Front Shock Absorber With Coil Spring: Disassembly”.

 

4. Once the front strut assembly has been disassembled, install the plastic sheet on the NEW front spring bumper and replace the coil spring.

 

5. Reassemble the front strut assembly.

Refer to TIS, 2006 or 2007 model year RAV4 Repair Manual, Suspension – Front Suspension – “Suspension: Front Shock Absorber With Coil Spring: Reassembly”.

6. Install the front strut assembly.

Refer to TIS, 2006 or 2007 model year RAV4 Repair Manual, Suspension – Front Suspension – “Suspension: Front Shock Absorber With Coil Spring: Installation”.

7. Once the struts have been installed in the vehicle, perform an alignment correcting any change in camber and toe.
8. Road test the vehicle to confirm that the “knocking” noise is NO longer present and that the vehicle is aligned.