Clunk after installing Bilstein shocks

[Synchromesh]

Installed a full set of B6 Bilsteins front and rear on my '84 Carrera recently. The car originally had green Bilsteins and they were still on the car 37 years later. The whole job took longer than anticipated due to lack of 7mm punch for the pins and self-locking top nuts for the fronts. But they finally arrived and it was done. I changed the big rubber shock mounts to Rennline ones - ***** of a job but done now.

Took it for a drive today and there is a clunk on the left front side only. It seems to happen on the bumps and appears to be coming from the top. Can be replicated by getting the car to go up and down even when static.

So far I retightened both top nuts with an impact wrench, checked suspension, pins, etc. Everything seems to be in order, except for some reason the strut bar is loose. It wasn't before.

Any ideas where to look next? Could the dust jacket be hitting anything?

[rokemester]

I recently finished up a suspension refresh on my 87 Targa. I needed to add a hard rubber spacer to stop a clunk from passenger side. Cut a thick rubber washer from this old suspension component.



Check other Bilstein/Boge suspension threads here.

[Synchromesh]

I saw that before but these aren't Boges. These are factory Bilstein shocks with a pin at the bottom. I believe the work a bit differently since they're an identical replacement?

[john walker's workshop]

Are you sure the pin captured the notch in the shaft?

[Synchromesh]

Originally Posted by john walker's workshop

Are you sure the pin captured the notch in the shaft?

Pretty sure but how would I check? I mean if it didn't wouldn't the shock not compress fully?

[racer_X]

Did you change the ride height of the car? If so, you may need to adjust the bump stops. If you did not change the ride height of the car, you will need the previous bump stop spacing.


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[Synchromesh]

Originally Posted by john walker's workshop

Are you sure the pin captured the notch in the shaft?

Yup, that solved it. Took it apart again and was able to yank the shock out with pin in place. Reinstalled properly - clunk is gone. Thank you.

[john walker's workshop]

I use a short punch just a bit narrower than the pin and capture the notch, then drive the pin in from the other side.

[rokemester]

Originally Posted by rokemester

I recently finished up a suspension refresh on my 87 Targa. I needed to add a hard rubber spacer to stop a clunk from passenger side. Cut a thick rubber washer from this old suspension component.



Check other Bilstein/Boge suspension threads here.

It’s been a couple of years since my suspension work. I’m noticing a clunk from passenger side at initial acceleration and slow speed. Don’t hear it over bumps, or at speed. I checked wheel bearings and they are adjusted properly.

[rokemester]

Originally Posted by rokemester

I recently finished up a suspension refresh on my 87 Targa. I needed to add a hard rubber spacer to stop a clunk from passenger side. Cut a thick rubber washer from this old suspension component.



Check other Bilstein/Boge suspension threads here.

It’s been a couple of years since my suspension work. I’m noticing a clunk from passenger side at initial acceleration and slow speed. Don’t hear it over bumps, or at speed. I checked wheel bearings and they are adjusted properly.