Mysterious front end clicking
 

I’ve had a mysterious loud clicking from the front end of my ‘78SC for awhile now. I have checked the tie rod ends and ball joints (they’re good). I replaced the struts and top strut mount bushings (they needed to be replaced) and the clicking persists.

I don’t have any issues with the steering wheel being off center and the clicking definitely sounds like it is coming from the front end, not the steering rack.

I visited a couple of my local Porsche specialists to try and sort this issue and all talked about the tie rods and ball joints until my visit to one of the specialists today. He mentioned that in the last couple of years he has had a few instances of the spindle assembly coming loose from the strut housing.

Apparently the spindle assembly is plug welded on the backside to the strut housing and this weld can break allowing the strut housing to rotate slightly in the spindle assembly. He said he has removed front wheel, rotor and backing plate to allow access to this area and put a couple of tack welds at the top of the spindle where it meets the strut housing, curing the problem.

Anybody heard of this issue and resolution?

http://forums.pelicanparts.com/uploa...1337208162.jpg

I heard a mechanic talked to me about it. I wonder what is the sight of this problem when looking closely at it. Have you tried (looking into it)?

If it turns out that the spindle assembly welds are broken, here is the RSR reinforcement that adds a great deal of strength.

http://forums.pelicanparts.com/uploa...1104723781.jpg

http://forums.pelicanparts.com/uploa...1109823542.jpg
From: http://forums.pelicanparts.com/porsche-911-technical-forum/199565-front-suspension-refreshening.html

If this is the problem and if you intend to reuse your struts, make sure the loose spindle assembly and shock tube aren’t damaged.

Best,
Grady

My first thought is the threaded gland nut that holds the shock to the strut. You have to jack the car up and lower the shock to be able to lift up the outer cover (#4 in the diag). If that is a bit loose the whole shock could be moving within the strut. Something else to check might be the wheel bearing play.
If that spindle is loose, you might be able to manually feel play by shaking the wheel once jacked up. That sounds very serious, I'd want to rule that out immediately. :eek:

When I replaced the struts I made sure that the gland nut that holds the strut down into the strut tube was very tight.

I've also confirmed that the wheel bearings are good and that the play is within tolerance.

Thanks everybody for the input so far. I love this place...

T.

p.s. gratuitous pic from the peak to peak hwy in the rockies

http://forums.pelicanparts.com/uploa...1337215482.jpg

Love those wheels!

I love that color.

You did not say what kind of SHock you were using? I had Koni's made (EIther here or the UK) that had a section in the travel that was not controlled. You could only tell this when the strut removed and when you pulled the shaft all of the way up or down there was a small section where there was no Control at all. this caused a slight noise when the wheel was in this section of travel. When I went to Dutch made Koni's this problem went away. Like others say it sounds more like the wheel bearing is too lose.

The shocks are Boge, replaced within the last year and I've also confirmed that the wheel bearings are good and that the play is within tolerance.

Thanks for the input...

Tom

Any chance there is a rock or other foreign material jammed between the brake rotor and caliper or dust shield?