Pop/Rattle suspension

[dagger108]

I have an '02 WRX wagon with 170k. Recently finished a suspension update - complete strut and spring replacement with Swift Sport Wagon springs over KYB ExcelG and new mounts. Replaced the outer tie bar and lower ball joints with Whitelines. Also replaced the front control arm and sway bar bushings with Prothane urethane bushings, and Kartboy endlinks. Had my local shop perform an alignment and check the torques.
I've only driven it a little since picking it up, because I'm hearing a pop/bolt rattling sound over pavement irregularities. It doesn't even take a big bump to make the sound, and doesn't correlate with turning (spring orientation). I know of the Kartboy Klunk and did an extra check on the endlinks (50 ft-lbs). The bushings are all well lubed. The sound remains.
Any ideas?

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[dagger108]

Lots of looks, but 0 comments?

[Bikelok]

When you do that much work on the car, it's tough to make a call. It could be a bunch of things.

Your best bet is to be methodical. Start where you think the noise is coming from.

Get up in there and poke, pull and move stuff around. Put a wrench on everything to check for looseness.

Good luck, let us know if there is more info you can provide.

[projectQWKSLVR]

I just did a similar suspension overhaul on my bugeye.

Maybe I missed it, but...

What are you running for top hats?
If you are still using the old worn out ones, more than likely the problem.

Here's why I think that. I was at 110k all stock front suspension. My first mod was the TIC fender braces, it really stiffened up the front of the car, made everything feel more solid. 5k later I started getting the noise you are talking about. 2 weeks ago I swapped the same KYB's with Tein H-techs and Whiteline Com C tophats. Nothing else in the front was done. Still have stock sway bar, links, ball joints, tie rods, and control arm bushings in the car. NOISE GONE!

If you did replace the tophats. The 19mm nut on top of the strut itself, where it tightens to the hat may be loose. Tq spec is 42ft/lbs. Check those!

[dagger108]

Originally Posted by projectQWKSLVR

I just did a similar suspension overhaul on my bugeye.

Maybe I missed it, but... What are you running for top hats?
If you are still using the old worn out ones, more than likely the problem.

Here's why I think that. I was at 110k all stock front suspension. My first mod was the TIC fender braces, it really stiffened up the front of the car, made everything feel more solid. 5k later I started getting the noise you are talking about. 2 weeks ago I swapped the same KYB's with Tein H-techs and Whiteline Com C tophats. Nothing else in the front was done. Still have stock sway bar, links, ball joints, tie rods, and control arm bushings in the car. NOISE GONE!

If you did replace the tophats. The 19mm nut on top of the strut itself, where it tightens to the hat may be loose. Tq spec is 42ft/lbs. Check those!

I replaced everything in the strut assembly, which was overkill for a few of the parts. The front tophats are Group N (TIC Rec - TY). I had tightened the 19's, and requested/paid the shop to tq to spec the suspension bolts.

Last night, I finally got the time again to put the car in the air and start checking. Yes, the 19's were loose. I pulled the assembly apart to make certain that I had the washers in (the other suspision, yes), so I don't have it all reassembled yet. (It's more than a 1 hour job for this noob.) Hopefully Sunday.

While I'm at it, I probably should check on the rears as well, and then pay a visit to the shop. Thanks for the input.