Spring makes a popping noise when I turn

[Sagaris]

I just replaced all my suspension and everything is great except for I noticed today that the front pass. side spring makes a popping noise when I turn full right lock. I am guessing that the upper and lower spring perches are not rotating in sync which is causing one end of the spring to rideup past the stopping point on the spring perch, then the spring perch snaps into sync with the other one and the sound I am hearing is the end of the spring popping back into place.

I felt the lower end of the spring and it is right up against the stop on the perch so that is not the issue there. I am guessing that I might have the strut nut too tight or that I just need to jack the car up and let it back down and let something settle.

Do you have any ideas?

[Sagaris]

The steering stuck on the freeway onramp today. :x

It did not return to center as I was exiting the curve. I was applying the brakes through the curve and it felt as if the brakes had locked up but I know that they hadn't. It was just the sensation of the steering not wanting to return that made me think that. I pulled over with the hazards on. checked all the bolts by eye + hand. got back in, and reversed back onto the main road. I turned into a parking lot and checked things a bit more thoroughly. I couldnt see anything amiss.

I said a prayer and drove white knuckled on the freeway with no further issue.

I got near home and went to a parking lot and tried to replicate the stuck steering by turning hard right and applying some brake. I coudlnt replcate it.
I got home and turned full lock to the right and heard the spring popping again.
I jacked the car up and it didnt make the sound with the wheels in the air (as anticipated) I checked and re-tightened all the fasteners.

With the car back on the ground, I removed the strut nut on both sides, applied some loctite and re-tightened them, not as tight as before (bought a torque wrench for the suspension install but it does not work properly).

The spring still pops at full lock to the right but I have not had any more steering sticking.

It seems like the car turns to the right sharper than it turns to the left but that still should not matter ................



Wait a second. Im gonna go look at the spring hat (15mm drop hat) I just felt inspired that it might be digging into the strut tower due to the asymmetrical design....

[Sagaris]

My inspiration was correct.

The spring hat is digging into the inside of the strut tower. :|

I took everything apart and ground down the corners of the hats and as much mateial as I could (not very much at all, perhaps a millimeter at most) There is simply no way around it.

Stock spring hats would not rub since they reside lower down in the strut tower. Since the strut tower gets more narorow towards the top the drop hats, which reside higher up in the strut tower, make contact with the strut tower when everything moves and flexes the right amount.

I really hope this never happens again!