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
- Test drive the vehicle and confirm the condition.
- 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”.
Refer to TIS, 2006 or 2007 model year RAV4 Repair Manual, Suspension – Front Suspension – “Suspension: Front Shock Absorber With Coil Spring: Disassembly”.
- Once the front strut assembly has been disassembled, install the plastic sheet on the NEW front spring bumper and replace the coil spring.
- 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”.
- 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”.
- Once the struts have been installed in the vehicle, perform an alignment correcting any change in camber and toe.
- Road test the vehicle to confirm that the “knocking” noise is NO longer present and that the vehicle is aligned.
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