[s-cars] front suspension noise

[Aaron Ryba]

I just replaced entire suspension system with H&R sport and Bilstein sports, Igor plates, all new bushings everywhere, etc. Everything dialed into spec properly.

I am experiencing a strange knocking/bump noise when the front suspension travels up. It only happens when going over speed bumps or other large bumps faster than normal. I have been checking and rechecking that everything is torqued properly and still no fix. 

The noise doesn't seem to happen on immediate compression but once the rear wheels go up over the bump (and front is down). The noise definitely comes from the front and I can feel it too.

The only thing I did non-Bentley style was to tighten the front sway bar bushing clamps at the subframe before the car was on it's own weight. This seemed impossible once the subframe was reinstalled as access to the bolt heads looked non-existant. Also used flour instead of talc powder on those new rubber bushings. I have no idea if this is the issue but it does sound like the sway bar is making the noise. Maybe some part of the H&R coils is catching?

Is this the internal bump stop in the Bilstiens? or the full compression of the springs? It doesn't seem like I should be hitting that so soon.

I was very attentive to reassemble everything as required so I am perplexed about the noise. Haven't had a helper to put some weight on the front end to try to replicate the movement, also pretty hard to do with the stiffer springs.

Anyone have an idea of what this is?

TIA
Aaron Ryba
95 S6 145k mi




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