Front Suspension Help

zachsbug · 07-28-2005, 06:13 PM

This spring I replaced all the components on the front suspension of my 68 T. New ball joints, updated to turbo tie rods, replaced the a-arm bushings with the poly ones, new HD Bilstein inserts to replace the Boge inserts, poly upper strut mounts & a strut brace.
With all this new stuff under the front end it really handles nice. The problem that I'm experiencing is that there is a clunking noise coming from the front when there is bump in the road. No obscene clunk when the road is decent. Ive been told that with the poly bushings you will have more road noise but this isn't road noise. I've checked everything to make sure everything is tight but I have reached an end. I don't know what this noise could be. The car never made this noise before I replaced everything. Could the Bilstein HD"s be to stiff? Can anyone offer some advice?

patkeefe · 07-28-2005, 06:29 PM

I have the same problem, except in the rear. New suspension and Bilstein Sports. I have been going crazy trying to isolate the source. I have been under the car with my stethoscope, while the kids and girlfriend bounce the car, and the only noise I can find is somewhere in the shock. I ought to call Bilstein and ask about the internals. Bilstein has a toll free number, and are very helpful; I have spoken to them before on other questions.
Pat

zachsbug · 07-28-2005, 06:36 PM

I've tried bouncing the front but with everything new up there the is not much movement. I jacked the car up & tried to move the hole strut assembly to see if I could make the noise but cant duplicate it. I don't know whats up.

Jim Smolka · 07-28-2005, 06:38 PM

Check that the notch on the ball joint matches the one on the A-Arm.

zachsbug · 07-28-2005, 06:48 PM

A notch? I don't remember seeing a notch but that was a couple of months ago that I did the install. I will have to take a look. Is the notch on the round part that actually has the joint in?

Jim Smolka · 07-28-2005, 06:52 PM

Assuming the ball joint is like the one on the 86, there is a notch on the outside of the ball joint that mates up to a cut out in the A-Arm. Don't ask how I discovered this...

patkeefe · 07-28-2005, 06:53 PM

Check to make sure the control arms don't bind due to the poly bushings

Zeke · 07-28-2005, 08:06 PM

Quote:

Originally posted by patkeefe
Check to make sure the control arms don't bind due to the poly bushings

What he said. I went off the track and banged things up pretty good. I used Elephant Racing's low friction mounts and I thought if I loosened the bolts and tapped things with a rubber mallet, that everything would re-center. Well, it apparently didn't and I will be removing the t-bars and the strut inserts to evaluate the situation.

That is really what you need to do, take the forces off the suspension and move it thru its range. If there is binding, you will find it this way. Suspension that is bound up is like your elbow or knee. When things aren't quite right, they crack. Well, maybe you're a young'un and they don't, but you know somebody whose joints do and that's what hapens in the suspension. Get it all freed up and these noises will disappear. If they don't, something is broken or about to break, like the various panels in the tub the make up the unibody and provide the suspension pick up points. That is much more rare than a simple binding problem, but worth looking into when the problem is persistant..

kucharskimb · 07-28-2005, 09:27 PM

if it's not stiction...

have you looked at the length of the rubber snubber that is under the dust boot around the upper portion of your struts? if they are original length (about 3.5"), you may be bottoming out against the snubbers.

on average, i'm guessing you need about +/- 2" of travel from static. mark the position of the dust cover on the lower portion of the strut with a marker. jack up the front end. remove the wheel. undo the top nut on the strut and lower out the strut from the fender. remove the dust cover. hold up the dust cover next to the strut using your marker line and look at how much travel the snubber will allow at its current length. cut it down as necessary. reassemble...

best of luck.
matt

Early_S_Man · 07-28-2005, 11:28 PM

zach,

It is probably something simple ... like the ball-joints through bolts not being torqued to spec! No notch on the '65 - '68 ball-joints, but there are two hefty bolts per joint holding them to the control arm!

livi · 07-29-2005, 01:35 AM

Posted recently about a similar problem. Didn´t get any replies, though.

After fitting new Bilstein in the rear car started to clonk over bumps. Never did with my original Boge. Strange....

zachsbug · 07-29-2005, 04:14 AM

Thanks for all the replies, I just don't know what to do anymore but will look into things. Zeke, I know what you mean about the joints.