Clunking Noise in Front End On Turns (Reposition Idler Arm and Power Steering Gear Box)

Some customers may comment on a clunk noise on turns. Also the customer may have been advised during a state vehicle inspection to return to the dealer for a front end inspection.

This noise may be the inner right tie rod making contact with the frame on left turns.

Inspect for wear / damage in the idler arm / pitman arm and the inner tie rod. If necessary, replace the parts. If a clunking noise is present when turning left, follow the procedure below.

1. Raise and support the vehicle.
2. Remove the engine protection shield.
3. Remove the two 10 mm bolts, the two 13 mm nuts and swing the sway bar down to gain access.



4. Turn the wheel 11 degrees to the left and the right, lining up the inner frame rail with the tie rod end boot as seen in the illustration above. Measure the distances between the inner frame rail and tie rod end. If the measurement is less than 14 mm (0.55 in), an adjustment will have to be made.
5. If the idler arm side needs adjustment, remove the idler arm. Refer to Idler Arm Replacement in SI.
6. Put the idler arm in a vice and use a 5/8 or 16 mm drill bit and enlarge the lower hole in the idler arm.
7. Reinstall the idler arm and bolts and tighten just the top bolt.
8. Reinstall the idler arm to the relay rod and tighten the nut.

Tighten
Tighten the nut to 63 N·m (47 lb ft).

9. With the aid of an assistant, rotate the idler arm clockwise to make the adjustment of 14 mm (0.55 in) and tighten the bottom bolt.

Tighten
Tighten the bolts to 150 N·m (111 lb ft).

10. Loosen the three steering gear box bolts.
11. With the aid of an assistant, rotate the gear box counterclockwise to gain the adjustment of 14 mm (0.55 in) and tighten the three bolts.

Tighten
Tighten the bolts to 150 N·m (111 lb ft).

Important: Side to side measurement should not exceed 4 mm (0.16 in). See the chart below.

12. Install the sway bar.

Tighten
Tighten the sway bar nuts and bolts to 46 N·m (34 lb ft).

13. Install the engine protection shield.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).

14. Place the vehicle on an alignment rack and check the toe.

For vehicles repaired under warranty, use: