Bilstein strut clunking kunumdrum?
 

Bilstein strut clunking kunumdrum. I have a clunking noise coming from both left and right front of 86 911. Have looked at entire suspension and not yet determined cause. Car has 2 year old suspension upgrades including Smart sway bars, Sanders torsion bars, RSR revalved struts, Elephant poly-bronze bushings, mono balls etc. I have lubed bushings (they have zerk fittings) etc but cannot find clunk source. Thought shock came loose from inside of strut housing so dropped the top from mount (see photo) but found that strut appears to be permanently sealed with steel cap. My question is: Is top cap removable? Is assembly able to be reassembled without compression press? I don't want to destroy any parts so figured I'd best ask this learned board.Any suggestions appreciated.
EP Slick - Arizona Territory

http://forums.pelicanparts.com/uploa...1309800260.jpg

There is a bushing in the top of the strut that sometimes wears, and will clunk... however I don't think two year old struts would wear like this,

Also you don't need a strut compressor to dis-assemble the strut. There is a roll pin on the bottom of the strut just above the wedge bolt ..drive that out, then pull the insert

EP,

Clunking is kind of vague! Is there play between the insert and green body? Is it a wheel bearing?

If all seems solid look at the front torsion mounts where the spherical washers are used. If this are over torqued which is easy to do, then this will cause a nice clunk and should not be driven! Ask me how I know?!

Could also be in steering rack. Vibrations???

The roll pins that hold the insert can break, too. Rare, but it happens.

Check ball joints, tie rods and camber mounts, too.

I had a Bilstein strut that was clunking - turned out it was bent

Edit: My clunking happened over bumps, driveways, etc.

No play between insert and green housing. Clunking sound happens when entering/exiting potholes, bumps, severely irregular surfaces. Sounds like something is unloading by maybe 1" and bottoming out with enough force to make the noise. No vibrations at any speed. Steering rack solid and secure. Wheel bearings good with hub properly secured. Don't know about spherical bearings on front torsion bar mounts but will investigate. Thanks

I would check the spherical washers at this point. You can do it visually and quickly. PM me if you need assistance.

I've had upper strut mount bearings wear out after a couple of years of track use, the bearings hammer into their races then start to make noise. Weren't ER monoballs though.
Might also want to check the spherical ends of the sway bar drop links to see if you have any slop in them.

Ed,

Good call. Maybe even a loose drop link.

Yea, I think driving all these performance oriented parts on the street is harder on the pieces than track duty.

I had the same clunking sound from the passenger side strut, removed the roll pin and it was grooved. Installed a new one and the clunking sound is gone.

Roger B.

Front torsion bar mount spherical...
 

Front torsion bar mount spherical assembly is poly-bronze with zerk fittings and move freely.

EPS