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10-08-2005, 11:27 PM | #1 |
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Vehicle:2002 WRX 5MT Sedan WR Blue. Cobb Stage 2 |
Clunk in front end since Prodrive & KYB Install
For the most part I think switching to KYB GR2 struts and Prodrive springs all around has been a big improvement. One thing bothers me though -- when the springs/struts reach close to full extension, I hear a noticeable 'clunk' sound.
I've done a search, checked hardware as recommended, and everything is tight. The only thing I noticed is that with the front end raised (suspension unloaded) the springs are not at all compressed -- I can rotate them a bit in the spring perches by hand. This is the only thing I can think of that may be causing this noise. The rears have rubber between the springs and top and bottom perches, but the fronts only have the rubber on top -- the bottom is metal on metal. Anyone else with this setup notice this? Is there any easy fix -- compressing the spring and slipping some rubber hose over the lower spring coil for example)? |
10-09-2005, 12:46 PM | #2 | |
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Quote:
AFAIK, Prodrives are designed to work with an OEM strut with no mod |
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10-09-2005, 03:23 PM | #3 | |
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Quote:
I can say that it definitely is not the bump stops -- it is a metal on metal 'clunk' -- as if something is shifting. I still have the front end up in the air. Everything is tight except the springs. They aren't about to slip off their perches, but I am able to rotate them a couple inches without using much force. |
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10-09-2005, 01:10 PM | #4 |
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tighten the top strut bolt- it's not tight enough... that's where I'll put my money.
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10-09-2005, 03:28 PM | #5 | |
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Quote:
I've heard people say to use an impact wrench. I have one, but that worries me because then I would have no way of knowing how tight they are. Any ideas? |
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10-10-2005, 01:21 AM | #6 |
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In one of the threads I read thru before starting this one...
http://forums.nasioc.com/forums/show...4&page=7&pp=30 ...Scotty recommended using LPS2 spray lube on the strut shafts to prevent the clunking sound. Anyone try this? Are there other sprays that work as well or better? Of course, even if this were to solve the problem, it would be temporary and I would think it would just be treating the symptom. |
10-10-2005, 03:42 AM | #7 |
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did you compress the front springs when installing them? prodrive springs are a bit trickier to install because its hard to get the spring compressors on and still be able to compress the spring enought to fully expose the threads of the spigot. At the most, I can usually only get two coils clamped ( you need to evenly clamp coils on both sides or you compress the spring unevenly). Even then, I need to press down on the hat in order to get the nut started as the spring isn't really compressed enough. There is a little lip on the spigot that the hat usually catches on and you might think things are snug but they are not. I always use an electric impact to tighten down the strut tops and just reach my hand in to hold the shaft to keep it from rotating. You can tell from the tone of the impacts that the nut is fully seated. I have one of those Sears supposed 200 lb0ft or torque impact wrenches. It has nowhere near that. After over 70 suspension installs, I have yet to hear any complaints of knocking from the strut tops or damaged strut internals not the strut spigot. Also, make sure you have the upper spring perch properly oriented.
Seriously, most noises coming from newly installed parts are usually because of faulty installs. Nice that you are an engineer but that doesn't necessarily mean you can properly install suspension. Believe me, there are enough subtleties in a suspension install that can lead to noise, improper alignment and lots of frustration. |
10-10-2005, 04:15 AM | #8 |
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Thanks Arnie, maybe I'll try the impact wrench.
BTW, I never claimed to be an engineer -- I only have an associates' degree -- but in my work as a train control tech I work on all sorts of electrical and mechanical equipment. In addition, I have worked on cars (as a hobby) for about 30 years. My experience is spotty though, for example, I have rebuilt engines but never a transmission. All I meant to imply was that I do have a clue. I was able to compress the springs all the way. In fact, I remember thinking that I had made extra work for myself by compressing them a little further than I had to. The tops went on easily and I tried to make sure that they were seated on the 'shoulder' below the threads on top of the spigot. I tightened the nuts down before releasing the compressor and everything seemed snug. Still, as I said above, I could have made a mistake. The only part of your post that wasn't clear to me was the following sentence: "After over 70 suspension installs, I have yet to hear any complaints of knocking from the strut tops or damaged strut internals not the strut spigot." I don't understand what you mean by, "...not the strut spigot."? I'm probably just being dense, but could you rephrase that sentence? Finally, in your experience, is it normal for Prodrive springs to be loose enough that they can be turned a few inches CW/CCW when the suspension is unloaded? Thanks! |
10-10-2005, 04:29 AM | #9 |
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My bad on using the word engineer! Not trying to insult your experience, I've just seen enough people who have loads of car experience make little mistakes that are particular to this suspension and scratch their heads!
Anyway, regarding the spigot...I'm trying to say that you shouldn't have to worry about shearing off the threaded portion of your strut with your electric impact wrench. I've installed quite a few with an impact wrench and not once have I damaged that threaded portion. I suppose if you keep hammering away, you'll eventually break it off but if you listened to that change in tone when the nut cinches down, piece of cake. Its been a few months since my last prodrive install, but I never noticed the springs being particularly loose in the perches, at least not so much that i could twist them a couple of inches. i could ask a buddy with Prodrive springs to jack up the front of his car to see if the springs are snug. Well, it sounds like you got the springs compressed enough and made sure the upper spring perch was safely beyond the shoulder. That's good. did you orient the upper spring perch correctly? I've also seen a few upper spring perches rotated 180 degrees opposite from where they are supposed to be. Lots of knocking there. Hmm, did you remember to put the rubber insulator between the spring and upper spring perch? What about the orientation of the dome washer? Is that on correctly? did you cut your springs?!?!? Just kidding. don't worry man, we'll figure this out! |
10-10-2005, 04:33 AM | #10 |
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oh, BTW, when you say "when the strut reaches close to full extension you hear a clunk" what situation is this in? flying over railroad tracks or dropping off of big dips or what?
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10-10-2005, 10:50 AM | #11 |
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.....do you have the strut upper perches 'pointing' in the right direction????
the holes gotta be oriented properly... |
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