Clunk on right front after suspension install

[ErykTheRead]

I just installed:
H&R Race springs
Bilstien Sports, front and rear
M3 rubber offset CAB
New tie rods
New urethane rear shock mounts
IE Camber plates in the front

Now I have a clunk coming from the right front wheel area. My sway bar bushings and end links are shot to hell, but I also had no clunk before the new suspension. The clunk happens when I unload the suspension slightly after a stop, just before I have stopped completely.

Pretty sure everything, including strut collars, camber plates, calipers, etc are all tightened down well.

The front right rotor is missing its retension screw, but I can't imagine the rotor is shifting with the wheel bolted down.

What are the possibilities? Is it possible the sway bar is now an issue with the large lowering? I have plans to replace in the near future anyhow, but it was odd that this appeared after the suspension install. One other thing: I did have to go with a new used strut housing and wheel bearing since mine was rusted to oblivion. Wheel bearing seemed good.

Another thing: When I jack up the left front corner, the spring (which is too short to be captive) falls out. Not so for the right side - the spring stays stuck. Not sure what holds it in, I guess just the friction of the rubber betwen the spring and the upper and lower spring perches?

Anything I have not thought of?

Thanks!

-E

[etxxz]

seems your car is WAAY too low for not having cut the front struts. you are hitting either the bump stop or the top of the strut if you have no bump stop... look at how much shock rod you have sticking out of the stut when you put the car back on the ground...if u can.

this is why i wanna get shorter shocks to be able to shorten the front struts and have optimal travel on my suspension...would hate blowin $500 shocks

for record and information purposes WHICH are the correct shocks to get ~ what car and what part number (koni/bilstein)?

[jlevie]

The clunk could well be from the front sway. To find out remove the link on one side and see if the noise disappears.

The H&R race springs are so short that they won't be in contact with the upper & lower perches when you jack up the car. So that's normal.

[ErykTheRead]

seems your car is WAAY too low for not having cut the front struts. you are hitting either the bump stop or the top of the strut if you have no bump stop... look at how much shock rod you have sticking out of the stut when you put the car back on the ground...if u can.

this is why i wanna get shorter shocks to be able to shorten the front struts and have optimal travel on my suspension...would hate blowin $500 shocks

for record and information purposes WHICH are the correct shocks to get ~ what car and what part number (koni/bilstein)?

This doesn't make any sense to me. If I cut the strut housing, the strut insert would be too large. Yes, my strut insert has more travel than the springs, but at the same time, I will probably bottom out my springs before I hit the bump stop on the strut. This is standard SpecE30 suspension setup.

Besides, the noise is at low speeds as the suspension is loaded or unloaded slightly. I am more inclined to suspect a binding ball joint, sway bar issue, or similar.

Thanks for the input though.

-E

Edit: Unless you mean cutting the strut insert? I cannot imagine the SpecE30 circuit requires a part that needs to be modified to fit.

[Dave]

This doesn't make any sense to me. If I cut the strut housing, the strut insert would be too large. Yes, my strut insert has more travel than the springs, but at the same time, I will probably bottom out my springs before I hit the bump stop on the strut. This is standard SpecE30 suspension setup.

Besides, the noise is at low speeds as the suspension is loaded or unloaded slightly. I am more inclined to suspect a binding ball joint, sway bar issue, or similar.

Thanks for the input though.

-E

Edit: Unless you mean cutting the strut insert? I cannot imagine the SpecE30 circuit requires a part that needs to be modified to fit.

No, I think he is referring to using shorter strut inserts - the Coraddo G60 inserts are sometimes used with a spacer or in a shortened strut housing. Ground Control sells them for use with their coilover kits.