Help! Front suspension noise
 

I recent installed a practically brand new MO30 front suspension including new control arms, hubs, tie rods and ends, rotors, calipers, camber plates, and the adjustable MO30 struts. Since the installation I have noticed that whenever I load and unload the suspension (bumps ect) it makes a distinctive *clunk* noise from both the drivers side and passenger side front. Now I have torqued everything to spec, checked, doubled checked and drove it for awhile and then re-torqued everything....yet the noise is still there. I should mention that I was not sure of the torque settings of the bolts that hold the strut to the camber plate, currently they are around 30 lbs from what I remember. However, there does not seem to be any movement at all in those plates. I should also note that the front struts were used for a month or so before I picked them up, but they are in almost perfect shape however, I did not take them apart and tighten down anything on them. Does anyone have any idea what could be causing this noise? It's really disheartening to finish such a big job only to have this noise not go away :confused:

Well, after pondering this over a late evening cocktail and now a morning coffee, the only thing I can come up with is to do the following.

Get the car up on a lift, load and unload the suspension on each side and see where your noise is coming from.

Based on your description, I would venture to guess one of the following:

1. Swaybars
2. Control Arms
3. Upper strut mount


AFJuvat

If it helps at all I noticed that it mainly makes the *clunk* when under many consecutive oscillations. In other words if you hit a larger bump I don't really hear anything, however if I car goes over many small humps in the road such that the it starts to bounce a little, the noise is very prevalent. I'm pretty sure its not the strut mount for I have check, tightened, checked, drove and rechecked them and did not see any movement. However, I did notice that if the suspension is unloaded and you push on the front coilovers you could actually move the spring back and forth a little bit (this occurs on both front struts). Is this supposed to be like that? :confused:

You obviously installed much stiffer springs, so there is much more stress on the suspension components. Maybe there were partially worn ball joints, the studs that go the the steering knuckle, etc. , which now seem to be moving more (while it was unknoticable before).
I would lift the front, and wiggle all joints in search of a suspect.

I will certainly lift the front of the car and check everything over. However, the entire front end including bushings, A-arms, ball joints, tie-rods and ends, rotors, calipers, sway bar and bushings ect. Are all brand new, or nearly so. Also, the front springs are indeed stiffer, rated at 350 lbs.

bump.............

DrFatz....What type of bushing is being used on the sway bar to A arm? I had a similiar issue and the bushing was out of round and would clunk from time to time.

They are just standard rubber bushings, although they are almost new. However, that would explain the noise under oscillation vs. just when you hit a bump. I will go and check the torque settings on them and make sure they are in good condition and seated properly. However, is it possible that the strut itself is making the noise?

Possible. The springs will slide on the housing when unloaded. I have mine tie wrapped at the top perch. This could be the source. Also when you replaced the springs and struts did you grind the lower perch mount down? If not this could be your issue resulting in the lower perch hitting the wheel.

You mentioned nothing about sway bars. Did you upgrade these as well? If yes then I would be looking at the sway bar mount on the A arms and a real good look at the bushings. I have seen many get out of round using the rubber type and if out of round you will get an intermittent clunk as the sway bars moves in the bushing.

Grind the lower perch mount? If I understand you correctly your talking about the difference in the Hub to strut mount. I actually changed to the Turbo A-arms, bushings, sway bar, mounts, wheels, rotors etc. Basically my car has a turbo suspension with MO30 struts and coilovers. However, the mention of the sway bars by several people has raised a good point. I will lift it up, remove the wheels and take a very hard look at those bars. :D

Lower perch on OE strut housing is larger and is ground down to accomodate the new springs when using a ride height adjustable coil over.