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After i recently put in raised King springs & new KYB struts, i've noticed a horrible "clunking" noise on rebound. Any time the front wheel moves downward more than gently (like when going over a tree root, pothole, or even up my drive!) i get a very loud "clunk" that i can even feel through the pedals. It only is the front (either side) & only on rebound.

We rechecked all the bolts, esp the top main strut nut...all tight.

We checked the bushes...all seem good.

I was hoping it was just the springs "bedding in" but in speaking to others no-ones had this problem.

I'm really worried something will snap when i'm out in the bush. People i've spoken to have no idea what it could be.

Has anyone on the forum had this problem?

Does anyone have any ideas?

A common problem when raising suspension with driveshafts.

I would say something is reaching a mechanical limit before it's even meant to.

When you break something, you'll then know where the design fault of mismatched parts is.

I have raised Heavy duty springs as well as 1" strut lift blocks and not an issue. Done 10,000km on them and they are still going strong. Im possibly considering adding another 1-2" strut lift blocks too 3-4" of lift over stocvk would be bloody awesome. But 2" does make a big difference at the present time

Possibly the front shocks/struts??

Taza

Think about the standard suspension and how it's designed.

The lower balljoints, outer tie rod ends and rack ends would be near on their limits when excessively lifted, especially at full droop.

littlewhiteute wrote:A common problem when raising suspension with driveshafts.

I would say something is reaching a mechanical limit before it's even meant to.

When you break something, you'll then know where the design fault of mismatched parts is.

Thats what i'm trying to avoid lol

I dont think anything is reaching a mechanical limit...there are others on here that have much bigger lifts than me.

Im guessing there's a worn bush somewhere we havent found

What we can rule out: strut top, ball joint, tie rod end, steering rack end, lower control arm bushes, sway bar link bushes.

That doesn't leave much else.

The whole strut has been out of the car and reassembled, and its unlikely we did it incorrectly twice.

I've had a similar noise come from a strut and turned out to be the extra shoulder on the top of the strut. When I say "shoulder", I mean the bit where the thread (at the very top of the strut) stops and the shock insert has a unmachined part where the Top Hat, Washer and Strut Top Mount all sit. I Found that the shoulder was longer than the original and when the whole thing was done up tight, it was really just tight up against this shoulder. This meant there was movement in those 3 parts, if there was no spring you'd fell it but with the pressure on the spring, it's very hard to see. If I had pics I could explain it better but hope you get the drift?

RSR 555 wrote:I've had a similar noise come from a strut and turned out to be the extra shoulder on the top of the strut. When I say "shoulder", I mean the bit where the thread (at the very top of the strut) stops and the shock insert has a unmachined part where the Top Hat, Washer and Strut Top Mount all sit. I Found that the shoulder was longer than the original and when the whole thing was done up tight, it was really just tight up against this shoulder. This meant there was movement in those 3 parts, if there was no spring you'd fell it but with the pressure on the spring, it's very hard to see. If I had pics I could explain it better but hope you get the drift?

I think i know what you mean, So what did you do to fix it?

nachaluva wrote:I think i know what you mean, So what did you do to fix it?

I added another washer in between the top mount and top hat. I had spares lying around but if you don't have any, just work out the thickness and pop down to your local bolt supplies.

OK thanks heaps...I'll give that a try

Nps.. the other thing to look at also is the swaybar bushes.

RSR 555 wrote:I added another washer in between the top mount and top hat. I had spares lying around but if you don't have any, just work out the thickness and pop down to your local bolt supplies.

HELP!!!

We tried putting the washer supplied with the strut UNDER the top hat where the machined shoulder is but it still clunks!

So i'm guessing this is wrong...do you mean under the strut top sitting against the strut top bearing?

Paul please help...I'm off to Mt Cole tomorow & not only am i sick of the terrible clunking but i'm worried the shocks will damage something, esp the rubber mount in the strut top.

As Princess Leia once said..."Help me Paul...you're my only hope"

EDIT: actually posted by Nachaluva on Venoms PC...sorry for the confusion!

removed phone number in fear of prank calls

Nachaluva:

Many thanks Paul, you've been a lifesaver. Will try putting the washer supplied between the mount & existing washer as discussed.

If it works (touch wood lol), I'll give KYB a call & abuse em! lol
Seriously I'll call em & suggest they put a note in their strut kit bout the changed design & the need for the washer & directions to use it.

Once again Paul...many thanks...

No probs, happy to help and any time.. Yeah, not sure why they did it and I'm sure it will catch a few more people out in the future.

RSR 555 wrote:removed phone number in fear of prank calls

Yeah i was gonna suggest that lol...
Thanks again Paul.

OK...i put the washer supplied with the strut above the tapered washer & below the strut top/mount...it still clunks!!! :-x

So then measured the distance from hub centre to wheel arch with the car on the ground then jacked up...total droop of 40mm RHS, 35mm LHS! So whats happening is the strut clunks as it reaches full extension with the spring still pushing down.

Ie, the strut is too short for the spring!!!

VERY frustrating!!!

This despite it being the strut specified on the King Springs website also confirmed by every auto parts store i called.

Even more frustrating! Grrrr....

nachaluva wrote:Yeah i was gonna suggest that lol...
Thanks again Paul.

OK...i put the washer supplied with the lift kit above the tapered washer & below the strut top/mount...it still clunks!!! :-x

So then measured the distance from hub centre to wheel arch with the car on the ground then jacked up...total droop of 40mm RHS, 35mm LHS! So whats happening is the strut clunks as it reaches full extension with the spring still pushing down.

Ie, the strut is too short for the spring!!!

VERY frustrating!!!

This despite it being the strut specified on the King Springs website also confirmed by every auto parts store i called.

Even more frustrating! Grrrr....

Damn.. good luck with that. Let us know how it turns out.

On the bright side we can now take out a set of shocks, disassemble them, reassemble them and put them back in a car in about 45 mins. Good practice for the DIYer.

Venom wrote:On the bright side we can now take out a set of shocks, disassemble them, reassemble them and put them back in a car in about 45 mins. Good practice for the DIYer.

Haha yeah we're getting pretty good at it lol
Would do it more often if i didnt need a WA after.

If I cant get no satisfaction from King Springs/ KYB then i might just have to put in standard springs in the front & keep the HDs in the rear...