[s-cars] Creaking Bilstein/Eibach/2Bennett set-up

[Steve Voit]

S-Heads:

I have a metallic-like creak or crack when I initiate movement from rest, or
turn the wheel such as to back out of a parking spot.  <Eibach/Bilstein/2B
camber plates, 95 S6 70k miles, well maintained suspension, no steering rack
attachment cracks>

I seem to have narrowed the noise to the camber plates as follows: I can
EXACTLY duplicate the noise by rotating the strut shaft via a hex wrench on
the top of the strut > turning this turns the shaft itself as well as the
spherical bearing (heim joint) on the camber plate.  The nature of the noise
is slip-stick: when it breaks loose it does so with a metallic 'crack' but
is quiet with further rotation until it comes to rest and is subsequently
'broken free' again.  You wouldn't expect this kind of noise from rotating a
shaft, but it's true.  It is 100% repeatable, and does not depend on the
amount of rotation.  My theory is that initiating movement of the vehicle,
whether with the throttle or steering input, causes micro rotation of the
strut shaft/heim joint assy thereby creating this noise.  Significantly, the
installation was quiet at first installation.

 

(I suppose it could also be a slip/stick noise in the shock itself between
case and shaft, which I have not isolated, but which my mechanic suggests
can be an issue w/ Bilsteins.  I've also received an email from a lister
that suggests improper washer thickness on top of the spherical bearing can
cause 'rattling', but this does not feel right to me and all looks tight.
I've searched the web to see if there is generic information on heim joint
noise, but have not come up with anything helpful)

 

How can I quiet this noise?   Any 2Bennett users out there?  

 

Suggestions welcomed!

Steve

S6 Seattle