Special Service Campaign: PZ, Special Coverage Extension, Front Cross-Member (TS 01 10080)

SPECIAL SERVICE CAMPAIGN: PZ, SPECIAL COVERAGE EXTENSION, FRONT CROSS-MEMBER

SERVICE CAMPAIGN BULLETIN

STATES

Connecticut, Delaware, Illinois, Indiana, Iowa, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, Washington DC, West Virginia and Wisconsin. 

CONDITION

In the snow belt states, corrosion may advance and cause rust-through perforation of the cross-member in the area of the left and/or right front lower control arm attachment brackets.

CAUSE

Some of the models listed have a front suspension frame cross-member that did not receive adequate corrosion protection.

CORRECTION

Suzuki will provide special extended coverage for corrosion failures of the front cross-member. If this condition occurs on listed Suzuki models within 12 years of the date that the vehicle was originally placed in service, or 180,000 miles, whichever occurs first, the condition will be repaired at no cost for parts and labor. The extended coverage is limited to the front cross-member and mounting hardware such as nuts and bolts only. If the cross-member shows signs of advanced corrosion or perforation caused by corrosion, the crossmember will be replaced. If the inspection indicates that the cross-member does not need replacement, the owner may return the vehicle back to a Suzuki dealer once every 12 months for another inspection, at no cost to the owner, for up to 12 years from the date your vehicle was originally put into service or 180,000 miles, whichever comes first. Refer to Campaign Bulletin SC-52.

PART(S) INFORMATION

Part Number	Description	Qty.	Reference #
45810-60G01-RX0	Frame, F Suspension	1	1
09135-12011	Frame Bolt No. 1	4	2
01550-1225A	Frame Bolt No. 3	2	3
09117-08098	Bolt, Stabilizer	4	4
09135-12005	Bolt, Lower Rod	2	5
01551-1025A	Bolt, Arm	2	6
01550-1040B	Bolt, Body	2	7
08314-4012A	Nut, Tie Rod	2	8
08316-1010B	Nut, Rear Bracket	2	9
09159-08083	Nut, Stabilizer Link	2	10

WARRANTY INFORMATION

Labor Operation	Description	Failed Part Number	Complaint Code	Defect Code	Labor Time
Please refer to the Campaign Bulletin SC-52 for claim submission instructions and labor times.

INSPECTION PROCEDURE

Required Tools:

12-16 oz. Hammer

3/16 in. Flat Tip Punch

1. Check vehicle history for any warranty claim(s) for inspection or replacement of the front cross-member. If an inspection or replacement has been performed within the last 12 months, inspection claims will not be paid. 
2. If the customer states the vehicle has symptoms that could possibly be caused by a weakening of the cross-member or related parts, an inspection and replacement may be necessary. In this case, a claim will be paid and the campaign will be closed for the vehicle. After the cross-member has been replaced no further inspections are required.
3. Raise the vehicle securely on vehicle lift.
4. Visually inspect the cross-member for perforation caused by corrosion. Replace the cross-member if perforation is identified.
   Fig 4: Identifying Crossmember

   
5. If no perforation is identified visually, continue the inspection.
6. Begin on the right side of the cross-member and using a 3/16 in. Flat Tip Punch and striking it with a 10-12 inch swing of a 12-16 oz Hammer, check the integrity of the crossmember at the locations described in the following steps. Replace the cross-member if the metal becomes perforated or displays a significant dent during the test.
   Fig 5: Identifying Right Side Of Crossmember

   
7. At the right side of the Cross-member strike the punch at the eight (8) positions indicated in the illustration. Four locations along the middle, and four approximately 1/2 in. above the lower flange.
   Fig 6: Identifying Crossmember Lower Flange And Total Height

   
8. On the underside surface of the crossmember test at the two locations which are approximately 1/2 in. in front of the retaining bolt and the three additional locations shown.
   Fig 7: Identifying Positions For Underside Surface Of Crossmember Test

   
9. Remove the front wheels.
   Fig 8: Identifying Front Wheels

   
10. Test the outside surface of the crossmember at the four illustrated locations (a longer punch might help if available)
    Fig 9: Identifying Positions For Outside Surface Of Crossmember Test

    
11. If there is no evidence of perforation found on the right side of the cross-member, repeat steps  5- 9 on the left side.
12. If the metal does not become perforated or display a significant dent after completing the inspection of the left side, there is no need to replace the cross-member. Reinstall the front wheel assemblies. Inspection is complete.
    Fig 10: Identifying Left Side Of Crossmember

    

CROSS-MEMBER REPLACEMENT PROCEDURE

Removal 

1. Hoist the vehicle and remove the front wheels. Using the appropriate Service Manual along with the following guidelines for reference, replace the cross-member assembly only if it has failed the perforation inspection in this bulletin.

   If you have questions, please contact your Suzuki Technical Manager or the Warranty Assistance Helpline at 714 996-7042.

2. Remove stabilizer link nuts, washers and cushions. When loosening link nut, hold the stud with a wrench.
3. Remove stabilizer mount brackets.
4. Remove stabilizer bar.
5. Remove right and left suspension arms.
6. Remove engine rear mounting nuts and engine mounting member bolts. Be careful to not lose the cushions and spacer which may stick to the cross-member.
   Fig 11: Exploded View Of Cross-Member

   
7. Remove the six cross-member bolts.
8. Remove the cross-member from the body.

   Installation 

9. Install the new cross-member to the body and tighten the six bolts to the specification listed.

   Crossmember bolt: 

   90 N.m (9.0 kg-m, 65.0 lb-ft) 

   Fig 12: Identifying Cross-Member Bolts

   
10. Install mounting member, spacers and cushions to cross-member and tighten the bolts and nuts to the specification listed.

    Crossmember mounting bolt: 

    55 N.m (5.5 kg-m, 40.0 lb-ft) 

    Mounting member nut: 

    45 N.m (4.5 kg-m, 33.0 lb-ft) 

    Fig 13: Identifying Mounting Member Nut And Crossmember Mounting Bolt

    
11. Install right and left suspension arms. Install stabilizer bar. Tighten all bolts and nuts to the specification listed.

    Front bushing bolt: 

    90 N.m (9.0 kg-m, 65.0 lb-ft) 

    Rear bracket bolt and nut: 

    50 N.m (5.0 kg-m, 36.5 lb-ft) 

    Stabilizer mount bracket bolt: 

    23 N.m (2.3 kg-m, 17.0 lb-ft) 

    Stabilizer bar link nut: 

    28 N.m (2.8 kg-m, 20.5 lb-ft) 

12. Install front wheels and lower vehicle.
13. Confirm front wheel alignment.
14. Road test vehicle.
    Fig 14: Identifying Front Bushing, Rear Bracket, Stabilizer Mount Bracket Bolts And Nut

    

For any questions concerning this special coverage, claim submission, vehicle eligibility, or any variation(s) to the inspection and/or repair instructions found in this bulletin, please refer to the Campaign Bulletin SC-52.

Should a vehicle present the same condition outside of the listed states above, please contact the Warranty Helpline at 714 996-7042.