[s-cars] Front Suspension clunking (still)

[Jack Gagnon]

Steve,

I just finished chasing down a front end clunk.   It would only clunk on
dirt roads occasionally and always on paved roads when flung violently from
side to side.  Replaced the control arms, still clunking, Replaced the
anti-roll bar bushings, still clunking, replaced outer tie rod ends and
upper strut bearing, no clunk. I think it was really just the outer tie rod
as I could see it move in the socket when raising the car with the floor
jack.

Jack



-----Original Message-----
From: s-car-list-bounces at audifans.com
[mailto:s-car-list-bounces at audifans.com]On Behalf Of Steve Voit
Sent: Wednesday, September 07, 2005 7:24 PM
To: s-car-list at audifans.com
Subject: [s-cars] Front Suspension clunking (still)


Hi Listers:

I have worsening front end noise on which I'd like your opinion:

*	Distinct noise (metallic-ish creak or clunk) (right or left side, or
both sides) principally when changing direction such as backing from drive
and then proceeding forward.  Most stop signs.  Sometimes simply when
braking and accelerating.  Or the crown jewel: backing and turning from a
parking spot in a hilly parking lot.
*	I had the 2 Bennett camber plates installed along with
Eibach/Bilstein about 7000 miles ago, and drive smooth roads.
*	After first hearing the noise I had my control arms replaced
*	More recently 4000 miles later I replaced my sway bar bushings and
tightened up all subfame mounts.
*	My sense is that it is lighter (lower mass) components that are
causing the noise, and that the subframe stuff is not causal.

Theories:

1.	Fenders liners not adequately trimmed.  This was 2Bennett's first
reaction, I'll check this although I have reservations because the noise can
equally occur during very quiet periods, suspension-wise, such as just
turning in a parking garage at creeping speeds, where I wouldn't expect
suspension deflection.
2.	Inadequate torque on strut inserts. (favorite theory) 2Bennett
suggest its difficult to achieve the 175-200 lb-ft torque on the strut
collar.  They have seen (only once) the lower part of the strut inserts make
noise under this condition.  Suggested that I tighten and/or machine a
spacer collar for the strut.  This dimensional situation was worse on older
cars such as 4000's where the diameter of the insert was very much different
from the strut housing.
3.	Play in metallic ball on Camber Plate.  2Bennett suggests the plate
was designed to be silent.  My mechanic doesn't think he's observing enough
motion at this location to make the noise.
4.	I recall listers commenting on noise resulting from an interference
b/w the sway bar and the conduit pipe that carries wiring across (under) the
engine.  I don't have information on this.



Any thoughts?  I want to check everything out as long as I'm spending the $$
to have a look.

Thanks in advance,

Steve in Seattle

95.5 S6

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