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NHTSA ID Number: 10143972

Manufacturer Communication Number: 02-001-18-3486a

TSB/Document Date: 2018-08-20


Summary

Some vehicles may exhibit one or more of the following noises from the front suspension. A squeaking noise from the front shock absorber when turning the steering wheel at a vehicle stand still caused by stick-slip between the front strut bearing and the coil spring. A popping noise from the front shock absorber when passing over speed bumps caused by the bump stopper contacting the strut bearing when the shock absorber is compressed. A creaking noise from the lower arm when driving over road bumps at 20-40 km/h caused by stick- slip of the front lower arm bushing. The noise occurs when the road surface is wet or after a car washing, and becomes more noticeable as the speed bump gets higher. To correct these problems, the following changes have been made. For the squeaking and popping noise, the shape of the bump stopper has been modified and a protector has been installed onto the coil spring. For the creaking noise, the friction of the lower arm bushing has been reduced by adding a dry coating.


Technical
Service Bulletin

MazdaeBay logo North American Operations
Irvine, CA 92618-2922

Subject:
POPPING AND/OR SQUEAKING NOISE FROM FRONT SHOCK
ABSORBER AND/OR CREAKING NOISE FROM FRONT LOWER ARM
BUSHING

Bulletin No.: 02-001/18

Last Issued: 07/13/2018

BULLETIN NOTES
This bulletin supersedes the previously issued bulletin(s) listed below. The changes are noted below in Red.

Previously Issued TSBs:
Date(s) Issued
02-001/18
01/05/18
02-005/17
03/16/16 and 01/13/17
02-001/16
10/10/16, 04/15/16, 02/23/16 and 01/08/16
02-004/15
05/12/15 and 04/24/15
APPLICABLE MODEL(S)/VINS
2014-2018 Mazda3 vehicles (Japan built and Mexico built) with VINs starting with JM1 and 3MZ

DESCRIPTION
Some vehicles may exhibit one or more of the following noises from the front suspension.



A squeaking noise from the front shock absorber when turning the steering wheel at a vehicle
standstill caused by stick-slip between the front strut bearing and the coil spring.
A popping noise from the front shock absorber when passing over speed bumps caused by the
bump stopper contacting the strut bearing when the shock absorber is compressed.
A creaking noise from the lower arm when driving over road bumps at 20-40 km/h caused by stickslip of the front lower arm bushing. The noise occurs when the road surface is wet or after a car
washing, and becomes more noticeable as the speed bump gets higher.

To correct these problems, the following changes have been made.


For the squeaking and popping noise, the shape of the bump stopper has been modified and a
protector has been installed onto the coil spring.
For the creaking noise, the friction of the lower arm bushing has been reduced by adding a dry
coating.

Customers having this concern should have their vehicle repaired using the following repair procedure.

Page 1 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. MazdaeBay logo technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

© 2018 Mazda North American Operations, U.S.A.

Bulletin No.: 02-001/18

Last Issued: 07/13/2018

REPAIR PROCEDURE
1. Verify the customer concern of noise coming from under the front of the vehicle when driving over speed
bumps and/or driving on a rough road and/or turning the steering wheel at a standstill.
2. If the noise has been confirmed, check the VIN and perform the appropriate repair procedure according
to the following tables.

Vehicle Spec
Vehicle Type A Vehicle Type B Vehicle Type C
JM1BM******** 100001 - 250356 250357 - 355940
N/A
JM1BN********
N/A
100001 - 156768 156769 - 999999
3MZBM******** 100001 - 195510 195511 - 330142
N/A
3MZBN********
N/A
100001 - 999999
N/A
Repair to Perform by Vehicle Type Vehicle Type A Vehicle Type B Vehicle Type C
1. Install Protector onto Spring
Perform DO NOT Perform DO NOT Perform
2. Replace Bump Stopper
Perform
Perform
Perform
3. Replace Lower Arm Bushing
Perform
Perform
DO NOT Perform

Page 2 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

© 2018 Mazda North American Operations, U.S.A.

Bulletin No.: 02-001/18

Last Issued: 07/13/2018

Protector Installation
3. Remove the spring according to the online instructions on MGSS (FRONT SHOCK ABSORBER AND
COIL SPRING DISASSEMBLY/ASSEMBLY).
4. Degrease 1.5 turns of the spring from the top.
5. Cut a thin strip of paper to 138 mm in length (or use a cloth type measuring tape).
6. Place the strip of paper (or cloth measuring tape) along the inner side of the coil spring starting at point
(A) and mark the spot on the spring where (B) is. (B) is the starting point for the protector installation.

7. Install the protector (A) onto the coil spring aligning the end (slant cut side) with the marking at spot (B).
NOTE: Install the protector so the gap (C) is evenly aligned around the outer edge of the coil spring.

Page 3 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

© 2018 Mazda North American Operations, U.S.A.

Bulletin No.: 02-001/18

Last Issued: 07/13/2018

Bump Stopper Replacement
8. Replace the bump stopper with the modified one according to the online instructions on MGSS (FRONT
SHOCK ABSORBER AND COIL SPRING DISASSEMBLY/ASSEMBLY).
NOTE:


Before removing the mounting rubber, mark its original position so it can be re-installed later to the
same position.
When replacing the bump stopper with a modified one, apply grease to upper side of the bump
stopper and to the inside of the bump stopper (on the surface that contacts the damper rod).

CAUTION: It is not necessary to adjust the front wheel alignment because the front shock absorber and
mounting rubber are not being replaced. However, make sure to install the mounting rubber to the original
position.

A Front Shock Absorber C Coil Spring
B Mounting Rubber D Bump Stopper

Page 4 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

© 2018 Mazda North American Operations, U.S.A.

Bulletin No.: 02-001/18

Last Issued: 07/13/2018

Lower Arm Bushing Replacement
CAUTION: Installation of the modified lower arm bushing will affect the road noise and the riding comfort in
a negative way. Therefore, only use this modified part for a customer vehicle with consideration of these
adverse effects.
9. Remove the front lower control arms (both sides) according to the online instructions on MGSS (FRONT
LOWER ARM REMOVAL/INSTALLATION).
10. Remove the front lower arm bushing using SSTs 49-G030-797 and 49-B025-004.
11. Place the SSTs on the front lower control arm as shown below, then press out the bushing.

Page 5 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

© 2018 Mazda North American Operations, U.S.A.

Bulletin No.: 02-001/18

Last Issued: 07/13/2018

12. Install the modified bushing using the same SSTs.
NOTE:




Before installing the new bushing, wipe the inside of the outer tube and make sure it is clean.
Apply soap suds to the bushing to ease the installation.
Always wipe off soap suds from the front lower control arm and bushing with a cloth.
Install the bushing so the projection (A) is pointing toward the front of the vehicle.

CAUTION: Make sure the bushing has been properly inserted by verifying that the bushing tab IS FULLY
EXPANDED as shown on the left (A). The bushing tab IS NOT FULLY EXPANDED as shown on the right
(B).

Page 6 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

© 2018 Mazda North American Operations, U.S.A.

Bulletin No.: 02-001/18

Last Issued: 07/13/2018

13. After installing the bushing, verify the distance between the front lower control arm (A) and front lower
control arm bushing inner pipe (B) equals 5.8 +/- 0.8mm as shown below.

14. Reinstall the front lower control arm according to the online instructions on MGSS (FRONT LOWER
ARM REMOVAL/INSTALLATION).
NOTE: For the joint sections with rubber bushings, raise the vehicle using a lift, and then temporarily tighten
the installation bolts. Then raise the vehicle using a wheel alignment lift rack (A) or lower the vehicle to the
ground (to load the suspension). Use a torque wrench (B) to tighten the bolts (C) to the specified tightening
torque.

15. Perform wheel alignment inspection and adjust if necessary.

Page 7 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

© 2018 Mazda North American Operations, U.S.A.

Bulletin No.: 02-001/18

Last Issued: 07/13/2018

PARTS INFORMATION
New Part Number Old Part Number
Description
Qty.
Notes
BAYN-34-111
B45A-34-111A
Stopper, Bump
2
For Japan built 2.0L
BPY4-34-111
B45G-34-111A
Stopper, Bump
2
For Japan built 2.5L
KDY5-34-081
-Protector
2
Type A vehicles only
9YB0-41-237
-Piston Rod Nut
2 Replace part for all models
TK48-34-470A KD35-34-470E Front Lower Arm Bushing 2
Type A and B vehicles
KDY5-34-470A
NOTE:


For Mexico-built vehicles that are originally equipped with the Bump Stopper (BJS7-34-111), use
BAYN-34-111 for the repair.
For Mexico-built vehicles that are originally equipped with the Front Rubber Bushing (BSJ7-34470), use TK48-34-470A for repair.

WARRANTY INFORMATION
Since two different causal parts (front shock absorber and lower arm) are involved in this repair, please
submit the claim divided into the following two claims.
NOTE:



This warranty information applies only to verified customer complaints on vehicles eligible for
warranty repair.
This repair will be covered under Mazda’s New Vehicle Limited Warranty term.
Additional diagnostic time cannot be claimed for this repair.

Page 8 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain Mazda vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

© 2018 MazdaeBay logo North American Operations, U.S.A.

Bulletin No.: 02-001/18

Last Issued: 07/13/2018

Front Shock Absorber


Vehicle Type A: Install Protector and Replace Bump Stopper
Vehicle Type B and C: Replace Bump Stopper

Warranty Type
A
Symptom Code
82
Damage Code
97
Part Number Main Cause
BAYN-34-111 or BPY4-34-111
Quantity
2
Operation Number / Labor Hours
XXK8NFRX / 0.6 Hrs.
Related Part and Quantity
9YB0-41-237
Piston Rod Nut 2 Vehicle Type A, B and C
KDY5-34-081
Protector 2 Vehicle Type A only
Front Lower Arm

Vehicle Type A and B: Replace Lower Arm Bushing

Warranty Type
Symptom Code
Damage Code
Part Number Main
Cause
Quantity
Operation Number /
Labor Hours
Sublet Code

Dealer Sublets Wheel
Alignment
A
82
93
TK48-34-470 (Lower Arm
Bushing)
2
XXK8NARX / 0.8 Hrs.
(Only replacement of front
lower arm bushing)
Z9

Dealer Performs Wheel Alignment

XXK8NBRX / 1.8 Hrs.
(Includes front wheel alignment check and adjust
using 4-wheel alignment tester)
---

Page 9 of 9
CONSUMER NOTICE: The information and instructions in this bulletin are intended for use by skilled technicians. Mazda technicians utilize the proper tools/
equipment and take training to correctly and safely maintain MazdaeBay logo vehicles. These instructions should not be performed by “do-it-yourselfers.” Customers
should not assume this bulletin applies to their vehicle or that their vehicle will develop the described concern. To determine if the information applies,
customers should contact their nearest authorized Mazda dealership. Mazda North American Operations reserves the right to alter the specifications and
contents of this bulletin without obligation or advance notice. All rights reserved. No part of this bulletin may be reproduced in any form or by any means,
electronic or mechanical---including photocopying and recording and the use of any kind of information storage and retrieval system ---without permission in
writing.

© 2018 Mazda North American Operations, U.S.A.

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TSB/Document ID: 02-001-18-3486a

Replacement Service Bulletin Number:

MFR Communication Date: 2018-07-13

MFR Internal Campaign ID/Software Version:

Communication Type: Service Bulletin/Repair Instructions

NHTSA Components: SUSPENSION

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