Suspension popping noise over undulations after suspension refresh

[InterlagosMC]

I’ve just managed to get my zed running again after nearly a year off the road while refreshing various parts and when I took it for a short drive today the suspension was great overall but when turning over undulating surfaces it seems to make a popping sound on the rear passenger side of the vehicle.

I thought at first it was the arb hitting the driveshaft so I extended the rear droplinks to give more clearance but the noise continues.

The rear subframe is polybushed and so is the diff, the lower camber arms have inner polybushes too but monoball hub joints. All polybushes were installed as per instructions the correct way round, I’ve just checked the photos before I rebuilt the car.

Does anyone’s have any experience of a similar issue or have any ideas what could be causing this noise.

Thanks
Andy

 

[Micke]

Might sound silly but first thing I’d do is to go through all the bolts and check that they’re tightened up to spec, don’t ask how I know :wink:

 

[enuff_zed]

Did you change the rear bump stops and dust covers?
I have had a similar noise and it turned out to be the bump stop sliding down the shock, meaning the plastic dust cover was tapping against the outer body of the damper.

 

[InterlagosMC]

Thanks for the replies, I did torque the bolts and paint mark them all but will check them again I guess, I went for kw suspension which came with new stops and dust covers fitted so doubt it would be that.

 

[Rockhopper]

The perils of fitting aftermarket stuff….I’ve head some will make noise as the spring coils touch each other over bumps.

 

[bigwinn]

The one I had experience of was that the ARB wasn’t centred correctly meaning it connected with other components

 

[Dark Diggler]

My thought would be the dust covers popping off at the bottom as the suspension reaches the max of its stroke I had this on a vehicle of mine after a full refresh, some grease on the strut and the inside of the dust cover minimised the noise until the suspension settled. Mine weren't coilovers though.

 

[InterlagosMC]

I’ll have a look at dust covers then, rear springs aren’t binding and I checked the arb yesterday as that’s what I thought it was initially, I have adjustable rear links so gave it more clearance but the mount points on the rear bar are almost at the bend so I’m pretty sure its centred

 

[InterlagosMC]

Little update

I had a look at the rear suspension today, the dust covers are fine and sit below the top of the strut. I cracked all suspension bolts off under load and re torqued them. I then thought I had solved it by finding the lower control arm touching the rear wheel hub but after changing that round to give clearance I still have this sound. I believe it to be my powerflex camber arms as the bush yo the subframe is pre installed and has no side to side movement but the outer bush is a monoball so I believe the noise is stress popping of the arm under articulation. I’m now looking at changing to millway camber arms which have a heim joint and I’ll do the same with the upper inner arm too.