Clunk from the top of my struts
 

If I push on the top of my wheels I can feel and hear a clunk. I took the wheel off and had my wife shake things until we narrowed it down to the top of the strut/shock. The top mount seems solid and it seems to come from the inner part of the strut top. I was already going to order new Bilstein inserts so is there anything else it could be so I don't get everything torn apart and end up needing something else?

There is nothing at the top but the mount and the insert, so if the mount is OK, it has to be a problem with the insert, or the collar nut has come loose.

I suggest buying the Bilstein collar nut wrench for torquing it properly. I found it for $4 online.

There is an upper and lower bushing in the bilsteins. The upper usually goes bad and has to be replaced, new inserts will not fix it. here are the bushings. common problem!

http://i30.photobucket.com/albums/c3...1/8639741b.jpg

Fonz,

What year car? Do you have Boge struts? Not sure about later cars but on earlier cars the Bilstein strut inserts require a spacer placed at the bottom of the strut or you'll get a clunk as described. Also be sure the aluminum gland nut is properly torqued. I believe the correct value is 93 ft-lbs. They used to come with the wrench but Bilstein USA now sells that separate for $6. You might also find this type wrench at a motorcycle shop. Be careful not to slip and bang your knuckle or fender when torqueing the strut.

I used to be stationed Tyndall. PC was good place to live.

Bryan

Cgarr +1

I had a clunk that AX tech inspectors always freaked out over... Thought it was a very loose wheel bearing... It was the upper bushing in the strut housing.

I replaced the upper and the clunk went away. Also installed new shocks at the time. It is a pain to draw out the old bearing from the housing. I used some threaded rod and a thick washer from a selection of old stuff I have. You will need to have the new bearing pressed in with an appropriate press tool/press. It is too deep and too tight a fit to fudge it in with a hammer and driver.

I would highly recommend checking other potential wear areas of the strut (like wear on the spindles) if the struts are high mileage units. I had bad spindles/ spun bearings also...

Good luck with your project.

Sorry, I guess I forgot to include important tidbits about my car. It is a 78 and has all green struts. The car has 85k and I'm not sure if they have ever been replaced.

Where can you get those bushings? Our host?

Try Chuck at Elephant Racing or call Bilstein USA.

This is a common Bilstein problem. Why I prefer Koni's

Here is my Bilstein Insert Fix:

http://forums.pelicanparts.com/porsche-911-technical-forum/591564-89-fix-if-not-loose-bearings-tie-rods-bushings-joints-strut-housing.html

8 Gauge Copper Wire, $0.89:
http://img.photobucket.com/albums/v5...212_105312.jpg

Acts as a SHIM to remove SLOP:
http://img.photobucket.com/albums/v5...212_120548.jpg