Snap/Popping Type Noise Coming from Front of Vehicle (Remove Bolt-In Front Crossmember and Add Washers)

This bulletin is being revised to add the HUMMER H2 model. Please discard Corporate Bulletin Number 03-08-61-002G (Section 08 -- Body and Accessories).

Some customers may comment on a snap or popping-type noise coming from the front of the vehicle. This condition is most apparent during hard left or right turns at low speeds. Going over bumps while turning may also aid in producing this noise.

Remove the bolt-in front crossmember and add washers using the procedure listed below.

Important: DO NOT slot the mounting holes on the crossmember as stated in previous bulletins. Slotting the holes has been found to be less effective and, in some cases, causes the noise condition to be more prevalent.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
2. Remove the mounting nuts, bolts and the front crossmember from the vehicle.
3. Clean all the undercoating off the crossmember in the area of the mounting holes.
4. Reinstall the crossmember with the bolts and nuts. On the driver and passenger side, add washer P/N 11509592, or equivalent hardened washer (see dimensions below), at each bolt head and nut location.

Tighten
Tighten the bolts to 120 N·m (89 lb ft).

5. Apply an even coat of Anti-Corrosion Coating, P/N 12346501 (in Canada, 10952414), or equivalent, to the crossmember where removed. Overlap the original coating in order to provide an effective corrosion protection.

For vehicles repaired under warranty, use: