Replaced Front Shocks - Clunk

[walt]

About 4-6 months ago I replaced the front shocks and ball joints and finally to around to a drive yesterday. Every minor bump in the road was followed by a clunk on both sides. With the car on jack stands I can lift the wheel and see the bottom half of the strut raise about 1/2" into the upper dust shield and clunk. Where is that play coming from, I do recall installing the rubber bumpers. These are Bilstein struts and inserts. Just wanted to get some opinions before taking this apart.

[OSC911]

I did completed a full front end overhaul and used Bilsteins HD. I didn’t use rubber bump stops as the Bilsteins have an internal stop and mention this in the instruction leaflet. Did you install the old rubber stops?

[wrxnofx]

If you put the car on jack stands and remove the front wheels, grab onto the strut and try to wiggle it back and forth. Does it do this?
https://youtube.com/shorts/5UvJEtbGU1E?si=ThhyE1KkPP4airKA

I have Boge struts with Bilstein inserts. There is a gland nut that holds the whole thing together under the dust shield. Mine was loose and was therefore responsible for that clunk. Not sure if your setup is the same but that’s what my clunk was.

[wrxnofx]

I used a gland nut wrench to tighten: https://www.ecstuning.com/b-bilstein-parts/strut-cap-gland-nut-wrench/tms189771/

[walt]

Originally Posted by wrxnofx

If you put the car on jack stands and remove the front wheels, grab onto the strut and try to wiggle it back and forth. Does it do this?
https://youtube.com/shorts/5UvJEtbGU1E?si=ThhyE1KkPP4airKA

I have Boge struts with Bilstein inserts. There is a gland nut that holds the whole thing together under the dust shield. Mine was loose and was therefore responsible for that clunk. Not sure if your setup is the same but that’s what my clunk was.

No movement at all in that direction. Different set-up.

[walt]

Originally Posted by OSC911

I did completed a full front end overhaul and used Bilsteins HD. I didn’t use rubber bump stops as the Bilsteins have an internal stop and mention this in the instruction leaflet. Did you install the old rubber stops?

I didn't reuse any rubber parts, only the new bumpers that came with the inserts. I recall a deteriorated rubber piece that fell out but thought it was the old bumper.

[blucille]

What was the torque setting for the ball joints?

[john walker's workshop]

Green or black struts?

[walt]

Green struts.

[OSC911]

Originally Posted by walt

Green struts.

I just fitted green shocks in Boge struts and mine didn’t come with any rubber bump stops. Only a little rubber ring on the shaft that is supplied to stop the supplied shock shields from hitting the nut during transport/shipping.

[emac911]

Years ago I replaced inserts on a zcar and had a clunk. Turned out the struts needed a spacer on the bottom. The insert was moving vertically. If you cant find it anywhere else, I would remove the strut and check the vertical play, like a previous post the gland nut may not be completely tight on the insert. I cant think of a way to check that on the car.

[john walker's workshop]

Green struts use a roll pin at the bottom to lock in the shock shaft. You may have missed the notch when the roll pin was reinstalled. Old rubber gets trapped in the bottom and keeps the shaft from going all the way down. Stick a punch in the roll pin hole to be sure the shaft is in place before knocking the roll pin back in.

[walt]

Originally Posted by john walker's workshop

Green struts use a roll pin at the bottom to lock in the shock shaft. You may have missed the notch when the roll pin was reinstalled. Old rubber gets trapped in the bottom and keeps the shaft from going all the way down. Stick a punch in the roll pin hole to be sure the shaft is in place before knocking the roll pin back in.

Thanks, I was thinking along that line but I do recall spinning the insert so I could see light thru the hole before driving the roll pin in. I'll check it.

[HorstP]

I had to glue some washer to the bottom of the shock. It was a hair too short so tightening the top nut did not fully grab the shock in the strut. This was with Elephant Racing shocks and ER had known that this is sometimes an issue.

[David Inc.]

Originally Posted by walt

Thanks, I was thinking along that line but I do recall spinning the insert so I could see light thru the hole before driving the roll pin in. I'll check it.

I think the strut has a notch all the way around it so spinning shouldn't matter. Maybe there was still something in there that you moved around that was blocking the hole, but the strut wasn't bottomed?

[john walker's workshop]

Use a punch about the size of the roll pin after you think the shaft is in the right place and then try to pull the insert out.

[walt]

Thanks guys, that's got to be it. Just ordered another roll pin.

[john walker's workshop]

Roll pin seam facing away from the shaft.