Front suspension clunk

[Charlie V]

I've been chasing a front end clunk for a long time. Always thought it was the brake cooling air ducting kit rattling on the lower control arm.

This morning I was under there and found it. With the car jacked up, the front wheels are just hanging there. As I was going over everything noticed the splined end cap with the front height adjuster is loose on the t-bar. As I wiggled it, it makes the same noise I hear as I go over rough roads.

I have the car lowered just a little below euro height. This clunking has been there since I dropped to this height.

So - any suggestions to correct?

I want to stay at the current ride height. Should the splined end cap be reindexed?? I remember when I installed they would only go in one way. However, the front suspension was hanging.

If they are loose on the T-bars, does that mean they are worn out?? The passenger one seems to have a little more movement compared to the driver side.

Thanks in advance.

[Trackrash]

From your description, I believe you do need to re-index the endcaps on the torsion bars. There should be tension on the adjusting screw, no matter what your ride height is.

BTW, while you are in there you should check to make sure your torsion bars are not rubbing on the inside of the crossbar.

[Charlie V]

Been thinking this through a little.

I do have tension on the "keys" with the car sitting. The problem is as the suspension travels and the car becomes unsprung, the tension on the keys unloads and they become loose and clunk away.

This only happens on rough/choppy roads and at higher speeds - likely when the wheel is going through its full travel quickly.

If they are reindexed, it will push the car up. Ummmm, no thanks. I'll do some more research on this one.

May post another thread with a more specific subject line

If others have insight, please chime in.

Cheers all.

[Trackrash]

I have wondered if my torsion caps would twist at full droop. I felt that it was allowing my front end to lift unnecessarily under acceleration.

Here is my attempt at a solution. Notice the nut on the adjusting screw.

[Charlie V]

Gordon, is this shot at full droop - car jacked up and wheels hanging??

Thanks.

[Trackrash]

That's with the wheels on the ground. But the nut prevents the torsion caps from moving more than perhaps 1mm when jacked up.

I believe the problem with the torsion cap moving has to do with the fact that we are using larger than stock torsion bars, mine are 22mm. In other words the stiffer torsion bar requires less pre-load, allowing the slack in the adjusting screw. A stock torsion bar would always have tension on the adjusting screw even at full droop?

I have wondered if any others have had this problem and needed a solution.

[Dave Kost]

Did this solve the clunk problem?

[Dave Kost]

The reason I ask is that I just when to 21mm tB's on the front and when going over choppy roads I can also hear a clunk.

[Trackrash]

I didn't have a clunk problem. Since I autocross my car, I wanted to limit the droop on my front suspension. That's why I added the nut. I'm just offering it as a possible solution.

I'm surprised this topic has not come up before.

[Charlie V]

Originally Posted by Trackrash

That's with the wheels on the ground. But the nut prevents the torsion caps from moving more than perhaps 1mm when jacked up.

I believe the problem with the torsion cap moving has to do with the fact that we are using larger than stock torsion bars, mine are 22mm. In other words the stiffer torsion bar requires less pre-load, allowing the slack in the adjusting screw. A stock torsion bar would always have tension on the adjusting screw even at full droop?

I have wondered if any others have had this problem and needed a solution.

Gordon, how much wheel travel do you have when you jack up the car?? Just thinking of what it would be like on the open road.

Thanks.

[Charlie V]

I should dig out my old tbars to verify. But the question I have, is the splined ends of the front tbars the same or are they offset similar to the rears?

[Charlie V]

good info in this thread..........

Front ride height adjustment: adjusting screws loose and car stiil too high

I will be reindexing the keys. Should be fun.

[Trackrash]

Originally Posted by Charlie V

Gordon, how much wheel travel do you have when you jack up the car?? Just thinking of what it would be like on the open road.

Thanks.

About 3 1/2 inches from wheels on the ground to full droop when jacked up. Keep in mind that my car is low. Front wheel well is 24" above the ground.

[Charlie V]

Thanks Gordon. Appreciate your input.

I have a 1500 km tour this coming weekend with a number of prior commitments before we leave on Friday. Not enough time to get into key adjustments before then. I will play with the suspension next week.

[Duane V]

Hey Charley
Mine had a clunk when we got back from the Thaw. Turned out to be a loose wheel bearing.

Duane

[BK911]

Make sure the nut that holds the strut inside the housing is tight.

[mspirito]

I have the poly bronze and had a clunk and found that the bushing assembly was loose inside the pinch assembly, tightened up the 19 mm bolt and it settled down! Anyone else have this happen.
I'm afraid it may have wallowed out the part that holds it, but for now seems tight

[Dave Kost]

Found my clunk…….

Battery not strapped down!

[Trackrash]

Our collective minds solve another mystery.

[Charlie V]

Fixed. This weekend will be the confirmation.

I was tightening up the front wheel bearings this AM. They were just a little loose. Had the car already jacked up and was looking at the torsion keys. Well, a couple hours later and the keys are reindexed and ride height adjusted. I think the adjusting took twice the time of reindexing.

I had the car jacked up with jack stands front and back. Then took my 2 floor jacks and with one under each front suspension, jacked up the suspension to remove the tension on the key. Removed the adjusting bolt, slide out the key and moved it down 1 spline on each side.

Adjusting height took a little time. A couple of short drives around the block and fine tuning and she was done.

As before, car is about 3/8" lower than Euro height. I like it at this height. However, I do scrape a little more on driveway approaches, etc. Just need to go slow on this stuff. Out on the open road - oh ya baby............

Thanks to the Pelican community and Trackrash's input, it finally clicked for me. As long as it does not clunk............

Cheers.