Clunking Front Suspension

[geeyore]

I've read several threads about clunking front suspension but mine has a little twist: it's all new.

Had the following installed on my 2011 E82 in the last month or so: Dinan front sway bar first, followed a few weeks later by Ohlins R&T, M3 lower arms, and Vorshlag plates. Aside from testing the damper adjustments on the Ohlins, I've made zero changes since leaving the shop.

I did have a front curb hit between the sway bar install and the rest of the suspension bits, but my own inspection and that of the shop indicated nothing needed but the full suspension swap - which was pre-planned - and an alignment (which had to be done anyway after the suspension install). Even the factory control arms were OK on inspection (but now replaced with M3 lowers).

The problem is that I'm now hearing - more and more pronounced over the last two weeks since install - a very annoying and persistent front-right "thump, clunk" over minor road imperfections, most noticeable at low speed (e.g., cruising through parking lots and paved residential/commuter side roads).

I visually and by hand checked all front-right suspension fittings yesterday, and everything seemed OK, however I'm not a mechanic. I checked the top mount for the Voshlag plates and one bolt needed just a very small amount of tightening. That didn't fix the "thump."

I'll of course contact the shop but thought I'd throw it out there for any comment or thoughts.

Thanks

[tuj]

having the exact same problem. common themes are new suspension install, vorschlag camber plates.

Is your problem on both sides or just one?

[chris82]

How good is the shop? Camber plates are tricky. Also would be easy to check out the sway bar end links and see if they're tight

[geeyore]

I took it back to the shop for inspection, and they did some overall tightening on suspension. Seems to be cured. I kinda think it was the top mount bolt on the Vorshlags, which visually seems to have been tightened about 1/8 inch or so (there was a noticeable mark on the bolt when I first looked at it). But that's just a guess, since I couldn't get to it myself due to tools and general laziness.

It was only the front right. In my first inspection (while at track) I went over the endlink pretty carefully. I don't think that was the problem. But at this juncture I don't know for sure, since it's apparently fixed.

[pj.rodriguez]

Originally Posted by geeyore

I took it back to the shop for inspection, and they did some overall tightening on suspension. Seems to be cured. I kinda think it was the top mount bolt on the Vorshlags, which visually seems to have been tightened about 1/8 inch or so (there was a noticeable mark on the bolt when I first looked at it). But that's just a guess, since I couldn't get to it myself due to tools and general laziness.

It was only the front right. In my first inspection (while at track) I went over the endlink pretty carefully. I don't think that was the problem. But at this juncture I don't know for sure, since it's apparently fixed.

I experienced the same thing. It was the top mount bolt. Even though it doesn't seem like much, turning it tight that 1/16 or 1/8 of a turn makes a huge difference.

[geeyore]

Originally Posted by pj.rodriguez

I experienced the same thing. It was the top mount bolt. Even though it doesn't seem like much, turning it tight that 1/16 or 1/8 of a turn makes a huge difference.

Thanks for that info, since it's kicking up again. I'll check it out tonight.

That intuitively seems like the source. When it first happened I thought I heard the plates clacking around.

[pj.rodriguez]

Originally Posted by geeyore

Thanks for that info, since it's kicking up again. I'll check it out tonight.

That intuitively seems like the source. When it first happened I thought I heard the plates clacking around.

Camber plates could also be a source of noise, but since my plates are the fixed Dinan plates, I knew it was most likely the top nut

[geeyore]

Top nut tightened and Loctited, which improved things.