Strut tops making clunking/metallic rattling noise

**-GT-** · 10-02-2006, 11:46 PM

Ok, i checked it out a bit more tonight, at 1st i can't get it to make the noise pushing it, but after trying several times and softening the shocks off i got it to make the noise when bouncing my whole weight on it, but only when i sped up the rate.

If i bounce it to get as much travel as i can it won't do it, but i found if i made it oscillate faster it did start knocking. I also managed to get the drivers' side to do it, but not as badly? With the shocks firmed back up it will still do it, it definately makes a difference how quickly it bounces???

This has got me stumped, not sure what's wrong with it now

**allencr** · 11-02-2006, 02:31 AM

I also managed to get the drivers' side to do it, but not as badly?

the driver side of the road is almost Always smoother then the passenger side, hence its increased pounding & wear.

**RWDboy** · 11-02-2006, 10:56 PM

You sure the shocks were good to start with that you put in there ? Sounds like something is worn in the shock absorber. Especially if the noise is related to the *rate* of compression/rebound of the spring.

**-GT-** · 12-02-2006, 09:29 PM

Nah, i was talking about when i was bouncing my weight on the car.

The shocks went in brand new 6 months ago and are perfect, the noise only started as soon as i put the cambertops on. Its definately either the tops themselves or something thats happened during installation.

The rate of oscillation has got me thinking too (been in melbourne for the weekend so haven't had a chance to check it out), is it possible that the play is coming from the top nut not being tightened all the way down, or some play in the way the top of the strut has been re-assembled? So that with the weight on it it sits down and at the strut can't react quick enough to rebound and keep pressure up against it?

Am i going to be right to drive it around a bit to take it somewhere? Will it cope and not do too much damage, or is every bump destroying my towers, tops and/or konis? I know thats a bit hard to answer without knowing exactly what's wrong but i want to move it tomorrow and its a 30-40 min drive but i'm worried i'll do permanent damage?

**45aken** · 13-02-2006, 09:18 AM

i hope you realise that camber tops (pillow ball, with no bushes) will make alot more noise than standard ones. is the gland nut that holds the shocks down tight also? if it isnt it will cause the shock to jump in the strut.

**Roundy** · 13-02-2006, 09:42 AM

Originally Posted by -GT-

is it possible that the play is coming from the top nut not being tightened all the way down

Originally Posted by Roundy

It is possible, mine wasn't clunking/rattling as bad as what u describe, but that did fix it. And yes with the weight of the car on it u can (normally) get it tight enough...just gotta be a bit careful otherwise it can spin.

if it is loose enough to rattle u will know as soon as u put a ratchet on it and try to tighten it!

**-GT-** · 13-02-2006, 12:14 PM

Yeah, cheers roundy. Sorry, didn't ignore it 1st time round, i just haven't had a chance to try tightening them; car is at gf's not near my tools, so hoping to not have to go get tools and come back. Think it's probably safer to at least try that or pull struts out at her place (PITA).

**Rodger** · 13-02-2006, 12:16 PM

I suggest as 45aken has.

Even though the shocks are new it only takes a millimeter or two in shock body movement in the strut to make a noise. The old rubber OEM tops may have been cushioning the sound.

Try the strut tube nut and see if you can tighten it a couple of turns. If not you may have to take out the shock and pack it up a few mil from the bottom.

Other things to check:

Are you using the original springs and spring top? Does/did the shock shaft have the notched step which goes into the original spring top? This helps stop the shaft rotating.

The OEM spring top may not be located onto the shaft correctly and when you check the top nut it tightens onto the top of this step and then would have three or four mil play as it moves up and down the notch. (hard to explain unless you see what I am discribing).

The OEM spring top may not centre and seat correctly onto the new strut top and may actually be moving sideways to create the sound.

Regards

Rodger

**-GT-** · 13-02-2006, 12:44 PM

Cheers rodger, some good stuff to check there. I think i'm going to pull them back out where they are and have a good look at how they've gone together and see if i can sort it out. The simplicity with which they went on led me to only cast a cursory check over them before putting them back in; think it's time for a more detailed inspection...

**-GT-** · 15-02-2006, 03:21 PM

Ha ha! Problem sorted!

I tried last night to tighten the top nut, and it did seem a bit loose, but wasn't comfortable that i'd tightened it enough, and it was still making the noise (other side had developed too) so i pulled the struts out again this morning. Also found out from talking to a guy who'd had some that these tops come with ~10mm spacers that sit between them and the upper hats. I hadn't seen anything like that in the box they came in so had another dig round in case they'd gone awol somewhere in the garage (they've been sitting in a cardboard box in the corner for weeks

) had no luck so made some up out of steel tube.

Went back down to the susp shop and re-assembled them, put them back in and gone for a drive and no noise! Feels good, seems to have fixed it, i think the new tops are thinner overall so without the spacer it was allowing the upper hat to come up further and creating some slack. You couldn't notice it when they were out of the car because at full extension it all sat fine, but with weight on it and bouncing it wasn't keeping the spring captive enough.

Thanks guys for the help and thoughts, looks like i'll be right for wakefield afterall

**mtp_69_i** · 09-11-2006, 10:56 AM

I've got this problem too, however it's come up after swapping the springs from OEM to Kings Lows (on an ST162). The front right shock (same side the noise is coming from) is out of gas. I didn't think much of it at the time (largely cos I'm a total suspension n00b) but the noise makes me think the strut insert needs replacing.

Co-incidently, the rear left is sitting higher than the rear right, I reckon this is due to the front right shock being shagged. The weight at the front is pulling the rear weight towards it diagonally across the car, hence the higher rear left.

I'm replacing the front strut inserts and will report back here with the outcome.

Cheers for a very informative thread guys! +rep

**mtp_69_i** · 10-11-2006, 09:12 AM

RIght,

Replaced the front strut inserts and the noise is gone and the rear of the car sits level now.

I guess this is a good lesson, if you're replacing springs, it's probably a good idea to consider replacing the shocks as well, it's just not worth the effort of getting the struts out again if the original shocks turn out to not like the change in spring rate.