Clunk noise from the front- help please

J

Jamturbo

Member
Hi,
I really need some help and advice. I have a 2004 e85 roadster, 56k. I have a clunk noise which is intermittent. It feels as if it is coming from the front, perhaps under my left foot. Car drives as well as possible apart from the clunk which is getting more frequent, perhaps 2-4 times.per trip. The clunk can sometimes be light or a bit more pronounced.

It can occur when
- I start the engine
- moving off
- going over a hump
- reversing and turning the wheel.

As I said, it doesn't always happen but it is driving me nuts. Car is booked in for next Monday for an investigation but I would really appreciate the collective wisdom of members so that I have an idea of what I might expect.

Thanks
 
Broken spring or worn front top mounts. Mine went when my 35is was less than 2 years old. They had worn away to nothing and it was metal on metal.
 
I changed the springs and shocks 4 months ago with new Suplex and B4 Bilsteins. I can't rule out that the springs might have gone but if so, very surprising. I also changed the top mounts. In fact every bit was replaced.
 
Come to think of it, I was sitting in the car at one point with the engine off and I heard a twang which went through the whole car. I didn't know what it was and the car drove fine after so I didn't think of the spring. I have never had a broken spring but is that twang the noise a snapped spring would make? I didn't make the connection as the springs are newish.
 
Jamturbo said:
Come to think of it, I was sitting in the car at one point with the engine off and I heard a twang which went through the whole car. I didn't know what it was and the car drove fine after so I didn't think of the spring. I have never had a broken spring but is that twang the noise a snapped spring would make? I didn't make the connection as the springs are newish.
Click to expand...
you can have a broken spring and not notice,if its just the pigtail end thats broken off.
Does the car make a twang noise whilst turning at a very slow speed this can also point to a broken spring.
 
Thanks. No twang noise since the big one a short while back. Will check out the nut at the top too.

I can't rule out that a new spring has broken.
 
1. Front mount top nut as suggested.
2. Lollipop bush worn. (though this I would expect to be more frequent knocks, over bumps etc)
3. Engine bay strut brace nuts not tight.

If components have been changed then it's always best to go back and check they're correctly fitted and tightened up first.
Also, changing some suspension components for new can transfer extra stress onto older components which can then give up shortly afterwards.
 
They may not have seated the new springs correctly in the bottom spring pan or on the rubber at the top. My clunk in similar circumstances was a very very slight loose engine bay brace.
 
Checked the braces, torqued up well. Thanks again for the shared wisdom. At least everyone is pointing to the same area.
 
Rockhopper said:
They may not have seated the new springs correctly in the bottom spring pan or on the rubber at the top. My clunk in similar circumstances was a very very slight loose engine bay brace.
Click to expand...

This, and insufficiently torqued nut on top of the strut would be my guess. Your big ‘twang’ noise sounds like the spring seating itself properly to me, if it was incorrectly positioned to start with.

Do you know if the top mount nut was torqued or just tightened with and impact driver? If the latter, I’d guess it’s not tight enough, even thought it will feel tight. Where are you based?
 
Im going top mount at end of life

I've got a video somewhere of mine doing it before replacement

Where you based if you are nearby you are welcome to pop over- can have a look?
 
Hi, based in Bromley, Kent. I torqued it up according to requirements but the more I am hearing, the more I start to doubt myself. I built each shock indoors then did a complete swap and did not re-use any parts.
 
Jamturbo said:
Hi, based in Bromley, Kent. I torqued it up according to requirements but the more I am hearing, the more I start to doubt myself. I built each shock indoors then did a complete swap and did not re-use any parts.
Click to expand...

Damn

Moved from biggin hill in 2011

Sorry matey
 
Just had another thought on this,when i had my suplex and b4s fitted i had the same clunk.
The car went back to the garage,it came out again perfectly sorted it turned out to be the b4s had a very slightly thinner bottom hole where the bolt went through to connect it to car.
This meant the bolt was very slightly too long,thus even though the bolt was tight it was not holding the shocker tightly to the car .if you want to pm me i can try to explain better over the phone . :thumbsup:
Ps this was only on the back as i remember ,i had front and back done on seperate occasions,think the fronts were fine with original bolt.but it made it easier to locate the problem because of this.
 
Were you able to stop the damper rod turning while you torqued down the top nylock bolt?
 
You mention a clunk on starting the engine as well ass on the move, so maybe engine or gearbox mounts on their way out?

I'd get under the bonnet whilst someone starts up, then check engine movement when revving up and for oil around mounts from the hydraulic filling.
 
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