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BMW 3-Series (E90 E92) Forum > E90 / E92 / E93 3-series Technical Forums > Suspension | Brakes | Chassis > Front suspension clonk E91



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      03-20-2013, 03:04 AM   #1
sknsean
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Front suspension clonk E91

Hi all

Sorry for starting another clonk thread.

I have a problem with my BMW e91 320d 177 hk from 2008, it all started when i lowered the car with a Eibach Pro-kit set, i also changed the original shock absorbers (The car have done ~125000miles) with Bilstein B4's(m-tech model). I also changed the top strut mounts with the ones from Sachs and the stabiliser bushings(FEBI).

The problem is the car makes a single klonk from the front right side, when the weight shifts from side to side when entering a roundabout at speed.
I can also produce the klonk when turning hard left, if I turn left again right after that the car is silent. But if I turn hard right and left again the klonk is back.
The sound is also present when running over deep pot holes at slow speed, I can't feel it in the steering wheel.

At first i retorqued everything to spec, the klonk was still present.
Then i contacted my mech friend we reinstalled the front right corner, sound still there and we tried the old strut mount, not any better.
Got the car allignled
I bought a new shock for the right side, added that together with the new strut mount.
Bought new stabiliser end links
Maybe the wishbone and the tension strut bushings that have worn out, so i bought the M3 wishbone and tension strut and got the car alligned.
I removed the front stabiliser and took the car for a spin, noise still present.
Yesterday i tried the old shock, noise still there.

I think I'm running out of options and my mech friend does not have any more ideas. The whole front end suspension on the car is new, and the sound of the klonk have not changed.

Could the strut brace make that noise?(It's torqued to BMW spec, tower 40nm + 60 deg and center 100nm + 100 deg)
Maybe a engine mount?
Wheel bearing?
Brakes? (Brakecaliper/Brakepads hitting the rotor?)

Please does anyone have any more ideas what to try?
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      03-25-2013, 04:51 AM   #2
sknsean
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Hi

This weekend i tried the new shock again and checked all bolts.
Same clonk, precise the same sound. So i think it has nothing to do with the strut assembly and/or the swaybar as i have tried without it.
I also tried to provoke the clonk with the brakes applied and it's still there so they can be cleared.

Have anyone, any ideas?
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      03-25-2013, 06:37 AM   #3
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Hmmm....so it is only the right side. Any clonk sounds I have in cars so far have been from worn bushings, and it often took several service guys to find it. You went through a lot of steps.
What about the way that the spring is seated into the suspension? Could that be moving somewhat?
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      03-25-2013, 08:33 AM   #4
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Quote:
Originally Posted by sknsean View Post
....another clonk thread.

First things first. Have you raised the front end; checked for wheel play?
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      03-28-2013, 06:38 AM   #5
sknsean
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Tomorrow i'll mount the new shock again and check for wheel play and make sure the spring i seated correct. I will also try without the clip for the brake (34116776526) maybe it will clonk more often.

Today i heard it again, the road dropped an inch or so. -------_____ clonk
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      04-07-2013, 02:07 AM   #6
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Yesterday i mounted the new bilstein shock again.
The clonk is still present, the spring is properly seated.
There no play in the wheel bearing, but i noticed that there where some play in the strut mount bearing. I checked my old strut mounts and there where play in them also, so i guess it's normal? Or is it?

I also checked the brakes for clonk sound with a rubber hammer, and couldn't hear anything. :-(
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      04-07-2013, 05:59 AM   #7
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Are you running new sway end links or using your stock ones? If you're lowered, it's possible that your sway end links are now not long enough. I'm assuming you bought adjustable sway end links for the front?
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      04-07-2013, 12:27 PM   #8
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With the Eibach Pro-kit you are 1cm lower than sports suspension... I don't think i need adjustable sway end links. The end links are from December.
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      04-07-2013, 01:07 PM   #9
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Quote:
Originally Posted by sknsean View Post
With the Eibach Pro-kit you are 1cm lower than sports suspension... I don't think i need adjustable sway end links. The end links are from December.
I'd try adjustable sway end links. Have a feeling that might be your issue.
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      04-08-2013, 07:12 PM   #10
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The problem is you upper and lower control arms. I am having the same issue and have visually seen movement in the bushings when turning the steering wheel from full lock to full lock.

Just reread your post and see you replaced with m3 upper and lower control arms. Strange that you seem to have replaced everything and still the same issue. Like I said i can visually see the bushings moving when going left to right. Are you replacing the items on both sides or only the one's you think are issues?

Last edited by NjRep335i; 04-08-2013 at 08:10 PM.
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      04-09-2013, 11:11 AM   #11
sknsean
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Quote:
Originally Posted by GreekboyD View Post
I'd try adjustable sway end links. Have a feeling that might be your issue.
I have tried uninstalling the whole sway bar assembly, and the noise where still present.

The items are replaced on both sides, the clonk is coming from the front right side...

Maybe the sound is coming from the passenger door, it rattles sometimes. Just a thought.
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