Clunk Pop or Click Noise when Transitioning Between Acceleration and Deceleration

Some customers may comment about a clunk, pop or click noise coming from the front of the vehicle during transition between acceleration and deceleration.

This condition may be caused by axle to hub spline movement.

To correct this condition, remove the axle nuts, apply Loctite 620® Retaining Compound or equivalent to the leading edge of both front axle splines, replace both front axle to knuckle nuts, and torque to 205 N·m (151 lb ft). Refer to the service procedure in this bulletin.

Caution: Make sure vehicle is properly supported and squarely positioned on the hoist. to avoid personal injury when vehicle is on a hoist, provide additional support for the vehicle opposite from which components are being removed.

1. Raise vehicle on hoist
2. Remove front wheel covers and/or wheels as necessary.



3. Remove and discard front axle nuts
4. When working on left axle, turn steering wheel to left lock; when working on right axle, turn steering wheel to right lock



5. Push and hold the front outboard CV joint inward.




Important: Retaining compound should be applied within the first 12 mm (1/2") of the leading edge of the axle splines. Apply only 3 drops to each axle and ensure that each drop is equally spaced at 120 degrees from each other around the spline surface. Excessive amounts of retaining compound will make disassembly of the joint difficult.

6. Apply one drop (0.5 ml) of Loctite 620® Retaining Compound or equivalent to each of three locations and equally spaced as shown in the illustration.
7. Slide axle through the hub.
8. Perform steps 4 through 7 for the other axle.
9. Install new axle nuts.
10. Torque both front axle nuts.

Tighten
Tighten to front drive axle nut 205 N·m (151 lb).

11. Install front wheels and wheel covers as necessary.
12. Verify repair.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for F4003 (Front Axle Nuts-Torque), or if another procedure is performed, refer to the appropriate electronic labor time guide.

Loctite 620® or equivalent is required to be applied to the leading edge of both front axle splines. Claims received in the amount of Retailer cost plus 40% parts allowance will be accepted for the material required to perform the repair. It will be necessary to sell Loctite 620® or equivalent to the CSO as "material" using net item code "M". Claims exceeding the amount of $5.60 (cost $4.00 x 1.4 parts allowance) will be returned with return reason 143 - material amount greater than maximum allowed.