2010 Land Rover Range Rover Sport (LS) V8-5.0L Technical Service Bulletin # TECLTB001234 Date: 091120

2010 Land Rover Range Rover Sport (LS) V8-5.0L Technical Service Bulletin # TECLTB001234 Date: 091120

Steering/Suspension - Front End Knock On Rough Roads

No: LTB00123

Issue: 4

Date: 20 NOV 2009

ISSUE '4' CHANGES ARE EXTENSIVE AND THEREFORE ARE NOT HIGHLIGHTED

SECTION: 204

Front Suspension 'Knock' Noise While Driving Straight Ahead

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AFFECTED VEHICLE RANGE

CONDITION SUMMARY:

Situation:

When driving over rough roads there may be a knocking noise coming from the front suspension while driving straight on rough / uneven road

surfaces. This could be caused by a number of different issues.

NOTE:

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

Action:

Should a customer express the above concern, follow the Diagnostic Procedure outlined in this bulletin to assist in identifying the source.

PARTS:

As necessary

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

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 joint:

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^ 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 STABILIZER BAR LINKS' below.

CHECK FRONT SUSPENSION STABILIZER BAR LINKS

1. Remove LH and RH front suspension stabilizer bar link lower nuts. (Figure 4)

2. Check the front suspension stabilizer bar link lower joints for freeplay by hand.

3. Check the front suspension stabilizer 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).

4. Undo the LH and RH front suspension stabilizer bar upper link nuts by one turn.

5. Tighten the LH and RH front suspension stabilizer bar upper link nuts to the correct torque.

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

^ Remove as necessary.

7. Install LH and RH front suspension stabilizer bar lower links.

^ Tighten the link nuts to the correct torque.

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

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

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

CHECK FRONT SUSPENSION STABILIZER BAR BUSHINGS

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

11. Inspect the front suspension stabilizer bar bushings for cracks, splits, or freeplay.

^ If no cracks, splits, or freeplay is evident, continue to step 3

^ If any cracks, splits, or freeplay is evident, refer to Technical Bulletin LTB00167. After installation of new bushings, continue to 'CHECK

FRONT SUSPENSION LOWER CONTROL ARM BUSHINGS' below.

12. Undo the front suspension stabilizer bar clamp bolts by one turn. (Figure 6)

13. Tighten the front suspension stabilizer bar clamp bolts to the correct torque. (Figure 6)

CHECK FRONT SUSPENSION LOWER CONTROL ARM BUSHINGS

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

^ 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

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

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

4. 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.

CHECK BODY MOUNT DAMPER NUT TORQUE - RANGE ROVER SPORT ONLY

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1. Check torque of the front and rear body mount damper nuts.

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

3. If any bushings have required replacement or torque-tightening has been required, road test the vehicle on the same route and check for 'knock'

noise.

^ If 'knock' noise is still evident, continue to 'CHECK BODY MOUNT DAMPERS' below.

CHECK BODY MOUNT DAMPERS - RANGE ROVER SPORT ONLY

1. Remove rear body mount dampers.

2. Road test vehicle to verify noise is eliminated / still evident.

^ If noise is eliminated, replace rear dampers.

3. Remove front body mount dampers.

4. Road test vehicle to verify noise is eliminated / still evident.

^ If noise is eliminated, replace front dampers.

^ If noise is still evident, install original front dampers.

FRONT SUSPENSION GENERAL TORQUE CHECK

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

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2. Verify torque of front differential cross member and undertray fixings. (Figure 12)

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

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

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

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