Clunk Endeth

["Al Powell" <apowell@agcom.tamu.edu>]

The clunk mystery is indeed solved.  My mechanic is calling his 
friends to brag on himself for finding the cause of my clunk - and 
which he suspects afflicts many, many Audis in the 5K/100/200 series.
He says that almost every car in this series he has seen with over 
80-90K miles has had an elusive clunk in the front end.

The problem was that the sub-frame bolt holes for the inner control 
arm bushings had become elongated.  It was worse in the top sub-frame 
bolt hole than in the bottom.  

I know full well that I tightened the pee-waddins' out of both of 
these bolts about a year ago.  However, considering the forces they 
must handle, it is reasonable to think that no tightening would 
prevent them from moving once they start to "wallow out" the bolt 
holes.

Aggrevating the problem is the fact that the sub-frame metal is 
actually pretty thin, it's easy to see how this could happen.  He 
wonders why Audi didn't make these mounting holes replaceable inserts 
- or offer a refurb kit.

At any rate, the fix is simple but NOT fun.

1)  Remove sub-frame.
2)  Find a source of used Porsche 944 head bolt washers.  (These are 
the ideal size, and aare supposed to be replaced every time the 944 
head is removed, so Porsche mechanics should have some.)
3)  MIG-weld one washer into place in the EXACT spot where the bolt 
hole should be.
4)   Re-install sub-frame.
5)  Align front end.

My clunk odyssey evidently has ended.  In the total effort to repair 
the problem, I  replaced:

Front shocks  (the RF was indeed toast...)
Strut bearings (do it while you're there...)
Sway bar bushings (cheap insurance)
Inner control arm bushings (ditto)
Front and rear sub-frame bushings (ditto x 3)
Rear motor mounts (at least one was bad anywho)

Total parts bill: @$250.

Total labor bill for installation and repair of sub-frame: $729.50.  
(12 hours labor - the sub-frame problem probably added at least 4.)

To put it in perspective, this month we had to make the equivalent 
of TWO car payments. But since the car is paid for and has only 82K 
miles, it's well worth it.  It drives superbly now and the front end 
is much more solid.


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Al Powell, Ph.D.                 Voice:  409/845-2807
107 Reed McDonald Bldg.          Fax:    409/862-1202
College Station, TX 77843      
Http://agcomwww.tamu.edu/agcom/satellit/alpage.htm
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