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Old 02-12-2007, 04:57 PM   #1
shinjyo
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Member#: 25808
Join Date: Oct 2002
Chapter/Region: SCIC
Location: South California(SD-OC-LA)
Vehicle:
2003 Impreza RS
STI---->Prodrive

Default My suspension clunks, please give me some idea

I have an 03 2.5RS sedan non turbo. around 63k miles right now.
Let me try to explain my situation in the most simple way. Hope you guys can give me some idea and suggestion.

1. 18000 miles, I spin out on the canyon road and hit on the mud and sand(right rear side). everything is stock on my car. every looks fine after it.

2. 32000 miles, the first time Autocross, everything still looks fine.

3. 34000 miles, I change my stock tires to BS RE950,still looks fine but the car started not align( which means my car go straight with steering wheel 2-3 degrees pointing left)

4. 36000 miles, i put a 20mm WRX rear sway bar onto my car. (it started clunking a bit, but i fix it by tighting all the bolts/nuts)

5. 42000 miles, i put JDM STI wheel with 225/45/R17 Falken ST-115 onto my car. the alignment started going worse. then i took my car to the dealership and do the alignment, they said they can't do it because of a bended right rear strut. they want to charge me for 360+labor to fix it. I didn't do it.

6. 48000 miles, I brought a set of used 04 STI Take-offs suspension(spring+strut with only 3300 miles used), i installed them myself with my friend's help(he has a WRX and he knows a lot about suspension). I used 04_ tophats. I took it to the shop and do the alignment, everything is great after that and no alignment issue and no clunking at all, just a bit bumpy ride.

7. 55000 miles, I went to the second time autocross, everything goes well.

8. 58000 miles, I got an accident that someone was out of control and hit on my left front side(bumper, bumper beam and left fender replaced).

9. 60000 miles, the suspension started clunking all the time, not obvious on the freeway, but it's a clear clunk noise(rear) when it comes to a non smooth surface such as a bump.

10. 60000 miles, I changed my sway bar bushings, clamps and bracket with 04+ WRX and hopefully i can fix the clunking problems, after the night i put everything on, the car is normal, no clunk noise, but after 2 days of driving, it starts clunk again.....

sorry for a long story and poor english, but i really want to see if someone can give me some idea, and any suggestion on what should i do now? take it to some shop and inspect it?

thank you so much!!
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Last edited by shinjyo; 02-12-2007 at 05:04 PM.
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Old 02-12-2007, 08:08 PM   #2
electricpork
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Member#: 9498
Join Date: Aug 2001
Chapter/Region: MWSOC
Location: Detroit
Vehicle:
03 Bugeye
Junkyards are fun!

Default

Yours is an extremely common occurrence with STi takeoffs. Here is a long and detailed thread covering it:

http://forums.nasioc.com/forums/showthread.php?t=520870

I had the problem too for a long time. The problem has temporarily been solved with the application of some grease to the strut body.

Best,

Ben
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Old 02-13-2007, 12:48 AM   #3
Kamikaze531
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Member#: 96347
Join Date: Sep 2005
Chapter/Region: RMIC
Location: Colorado Springs, CO
Vehicle:
2003 WRX Sedan
WRB

Default

Has anyone tried purging air from the strut? There's an explanation on page FS-22 in the Chassis section of the Impreza service manual.
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Old 02-13-2007, 07:28 AM   #4
Siper2
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Chapter/Region: MAIC
Location: Dillsburg, PA
Vehicle:
2007 BMW 328xi wagon
Silver

Default

Not sure about that, but Ben's suggestion is one of the only solutions we've found. Seems to work on my STi V6 struts.

It's a problem that's existed for well over 10 years. The EDM and JDM guys were dealing with it long before we did.
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Old 02-13-2007, 12:57 PM   #5
Kamikaze531
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Member#: 96347
Join Date: Sep 2005
Chapter/Region: RMIC
Location: Colorado Springs, CO
Vehicle:
2003 WRX Sedan
WRB

Default

I've been using the grease method for some time now, but I'm looking for a more permanant solution. I guess I'll try it and let y'all know how it turns out.
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Old 02-13-2007, 02:13 PM   #6
waktasz
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Chapter/Region: Tri-State
Default

I see the problem. You went 23,000 miles between autocross events. There's no way that's healthy.
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Old 02-16-2007, 10:43 PM   #7
Kamikaze531
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Join Date: Sep 2005
Chapter/Region: RMIC
Location: Colorado Springs, CO
Vehicle:
2003 WRX Sedan
WRB

Default

I've got the strut off now. There didn't seem to be any air in the strut, but I did the purging process anyways just to be sure. Anyone have other ideas I can try out before it goes back on?
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