2010 Land Rover Range Rover Sport (LS) V8-5.0L Technical Service Bulletin # TECLTB002042 Date: 091120

2010 Land Rover Range Rover Sport (LS) V8-5.0L Technical Service Bulletin # TECLTB002042 Date: 091120

Steering/Suspension - Front End Knocking On Rough Roads

No: LTB00204

Issue: 2

Date: 20 NOV 2009

ISSUE '2' CHANGES ARE EXTENSIVE AND THEREFORE NOT HIGHLIGHTED

SECTION: 204

Front Suspension 'Knock' Noise While Driving Straight Ahead

AFFECTED VEHICLE RANGE:

Range Rover Sport (LS) - Dynamic Response(TM) vehicles only

VIN: 6A900129 - Onwards

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Model Year: 2006 - Onwards

CONDITION SUMMARY:

Situation:

Vehicles with Dynamic Response may exhibit a 'knock' noise from the front suspension while driving straight on rough / uneven road surfaces. The

noise may be caused by a number of different issues.

NOTE:

For vehicles from VIN 7A983118 - onwards, Technical Bulletin LTB00241 must be performed prior to performing the Diagnostic Procedure below.

For vehicles within the VIN range 6A900129 - 8A122778 exhibiting a steering column 'knock' noise, refer to Technical Bulletin LTB00097. For

vehicles exhibiting a 'thud' noise, refer to Technical Bulletin LTB00198. For vehicles within the VIN range 6A900129 - 6A960521 exhibiting a

'creak / squeak' noise, refer to Technical Bulletin LS204-006.

NOTE:

The Diagnostic Procedure should be followed as written, with the most likely causes listed in order of the greatest benefit when addressed.

Action:

In the event of a customer concern of the above, refer to Technical Bulletin LTB00241; if after carrying out the procedure the noise is still present,

refer to the Diagnostic Procedure outlined below to assist in identifying the source of the noise.

PARTS

TOOLS:

Refer to Workshop Manual (GTR) for any required special tools

WARRANTY:

NOTE:

Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only. Always

refer to DDW to obtain the latest repair time.

DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.

DIAGNOSTIC PROCEDURE:

FRONT SUSPENSION UPPER AND LOWER ARM BALL JOINT CHECK

NOTE:

The majority of knocks can be heard at approximately 25 mph (40 kph) on rough roads or over single-wheel inputs / shock. It is important to identify

a test route that highlights the customer concern of suspension knock and re-test the vehicle over the same test route when identified in the following

procedure. The test route should include roads that have a broken road surface or drain covers that allows one wheel inputs etc. The vehicle speed

that highlights the issue should be noted during the initial appraisal of the customer concern and then replicated on subsequent test drives.

NOTE:

For current torque values, refer to Workshop Manual (GTR): GTR Home > NAS > Model > Service Information > Model Year > Workshop Manual

> 2: Chassis > 204: Suspension

NOTE:

If after replacement of an early type lower suspension arm ball joint the new type ball joint is 'loose' in the lower suspension arm, the lower

2010 Land Rover Range Rover Sport (LS) V8-5.0L Page 278

suspension arm MUST be replaced.

1. Road test vehicle and verify customer concern.

2. Inspect left-hand (LH) and right-hand (RH) front suspension lower suspension arm ball joints:

^ If early-type lower arm ball joint fitted, replace with later-type. (Figure 1)

^ If new-type lower arm ball joint fitted, continue to step 3.

3. Using the in-vehicle switch, lower air suspension to Access height.

4. Raise vehicle on a 'wheels free' lift.

5. Remove LH and RH front wheel / tire assemblies.

6. Remove front suspension spring / damper lower mounting bolt. (Figure 2)

7. Using a hydraulic telescopic jack, raise the front suspension RH lower arm until the distance from the center of the wheel hub to the wheel arch is

455mm (17.9 in). (Figure 2)

NOTE:

It may be necessary to lift the bar several times to displace grease present inside the ball joint.

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8. Using a suitable bar on the top of the telescopic jack and the bottom of the front suspension lower ball joint ballpin thread, lift the bar and check

for any axial play in the lower ball joint. (Figure 3)

^ If any axial play is evident in the lower ball joint, replace the lower ball joint.

^ If no axial play is evident in the lower ball joint, lower the suspension arm, install the spring / damper lower mounting bolt to the correct torque,

and continue to step 10.

9. Repeat steps 6 - 8 on LH front lower suspension arm.

10. If any suspension components have been replaced, install LH and RH front wheel / tire assemblies and road test the vehicle on the same route

and check for 'knock' noise.

^ If 'knock' noise is still evident, continue to 'CHECK FRONT SUSPENSION ACTUATOR BAR LINKS' below.

CHECK FRONT SUSPENSION ACTUATOR BAR LINKS

11. Remove LH and RH front suspension actuator bar link lower nuts. (Figure 4)

12. Check the front suspension actuator bar link lower joints for freeplay by hand.

13. Check the front suspension actuator bar link upper joints for freeplay by raising the link and letting it go. (Figure 5)

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^ If the link(s) falls under its own weight, replace the link(s).

^ If the link lower joint(s) has freeplay, replace the link(s).

CHECK FRONT SUSPENSION DYNAMIC RESPONSE ACTUATOR BUSHINGS

1. Refer to Workshop Manual (GTR) Section 501-02 and remove the engine undershield.

NOTE:

Freeplay between the actuator bar and actuator bar bushings is required for correct operation of the Dynamic Response system.

2. Measure the actuator bushing freeplay (Figure 6):

^ The radial freeplay between the actuator bar and actuator bar bushings must be no greater than 2mm (0.08in).

^ If the radial freeplay is greater than 2mm (0.08in), replace the actuator bar bushings

3. Undo the LH and RH front suspension actuator bar upper link nuts by one turn.

4. Tighten the LH and RH front suspension actuator bar upper link nuts to the correct torque.

5. Inspect the LH and RH clamping faces of the front suspension actuator bar lower links for surface flatness or weld splatter.

^ Remove as necessary.

6. Install LH and RH front suspension actuator bar lower links.

^ Tighten the link nuts to the correct torque.

7. Install LH and RH front wheel / tire assemblies.

8. Road test the vehicle on the same route and check for 'knock' noise.

^ If 'knock' noise is still evident, continue to 'CHECK FRONT SUSPENSION LOWER CONTROL ARM BUSHINGS' below.

CHECK FRONT SUSPENSION LOWER CONTROL ARM BUSHINGS

1. Check the front suspension lower control arm bushings for cracks, splits, or evidence of fluid leakage from the hydro-bushing. (Figure 7)

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^ If cracks, splits, or leakage is evident, replace as necessary.

2. Check for correct torque of front suspension lower control arm front and rear bushing nuts. (Figure 8)

^ If torque-tightening is necessary, the vehicle must be at correct ride height to prevent pre-loading of the bushings.

CHECK FRONT SUSPENSION UPPER CONTROL ARM BUSHINGS

1. Check the front suspension upper control arm bushings for cracks or splits. (Figure 9)

^ If cracks or splits are evident, replace as necessary.

2. Check for correct torque of front suspension upper control arm front and rear bushing nuts. (Figure 10)

^ If torque-tightening is necessary, the vehicle must be at correct ride height to prevent pre-loading of the bushings.

FRONT SUSPENSION DYNAMIC RESPONSE ACTUATOR AND FRONT DIFFERENTIAL CROSS MEMBER TORQUE CHECK

1. Refer to Workshop Manual (GTR) section 501-02: and remove the engine undershield.

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2. Using special tool 204-703 and 204-705, verify torque of front actuator clamp bolts. (Figure 11)

^ If clamp bolts are undone, new clamp bolts must be installed in the following order:

a) Middle bolt

b) Front bolt

c) Rear bolt

3. Check for correct torque of the front differential cross member bolts. (Figure 12)

4. Verify torque of control lower arm ball joint nuts and steering gear tie rod end nuts. (Figure 13)

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5. Check torque of front suspension Dynamic Response actuator arm flange bolts to actuator body. (Figure 14)

NOTE:

If the vehicle is deemed to have a poor knock noise level compared to other vehicles fitted with Dynamic Response with this issue or the knock noise

can not be directly diagnosed as coming from the front suspension, thoroughly inspect the Dynamic Response pipe routing.

6. Thoroughly inspect for Dynamic Response pipe-to-frame / body contact. Clear all stones and contamination from pipes and shields.

7. Refer to Workshop Manual (GTR) Section 501-02 and install the engine undershield.

8. If any torque-tightening has been required, road test the vehicle on the same route and check for the 'knock' noise.

^ If the 'knock' noise is still evident, contact the Land Rover Technical HelpLine.