clunking on front suspension...what could it be?

ssabripo · 02-14-2009, 12:06 PM

a couple of months ago I had some bad clunking going on my front passenger side suspension, and after inspection at the dealer, it turned out to be a bad shock (strut assembly)....they went ahead and fixed it.

fast forward, and a few days later I just said screw it and put some KW V2 coilovers, and all was well. About a week or so ago I started to hear a slight clunk again, on both sides but more pronounced on passenger side.

it's not as bad (no multiple clunks as I go over a slight bump, just a single clunk) as before, but nonetheless it has been getting louder with time!

I checked the top of the struts (3 bolts from engine bay), and they are tight. I checked the strut links, and seems tight.

what else can I check? what can be causing this clunking? The coils are not even a month old, so no way this is a busted shock on the coil, is it? I mean, it's not like I went to the track or went over bad bumps!

morscode · 02-15-2009, 12:36 AM

I would definitely say check the sway bars. My sway on the left side was OFF (nut missing), after I installed my coilovers and I always go over all the bolts twice at the end of the install.

Narrow down when you hear the clunk. Bumps,speed during bumps, turns

ssabripo · 02-17-2009, 07:15 PM

well I'll be damned! I think (keyword "think") I may have found an issue with KW coilovers for the 135i

So today Technic and I went to his house and looked at the suspension and tried to make sure all the nuts were properly secured, etc. When we looked at the nut that connects the coilover shock arm to the endlink screw bracket, we saw that the screw was somewhat loose, but the problem is that when we tightened it, there wasn't much to play with....

so we looked at his car, and saw that the screw is much larger on the M3/335i, and it has enough clearance to stick out a good 1/2" so that the locking nut's teeth (the ones that actually LOCK into the screw) could get a grip.

but it doesn't work that way on the 135i!!

there isn't enough screw clearance for the nut's teeth to grap a hold of the screw:

but in the M3, it does:

after looking at it more closely, it seems that the link screw is definitely shorter, which means the the coilover arm should have been "thinner" than the ones for the 335i......they should have known this!

So we tightened as much as we could, and put some lock gum, and so far, the clunk is gone!!

I will ride it a few more days over bumps, but this is definitely either a luck thing, or we found a defect on the 135i's version of the KW V2!!

Robert · 02-17-2009, 07:45 PM

Are you planning to inform KW v2 on this? I am putting off any suspension modifications with KW until there are more definitive answers.

Dangerlucas · 02-17-2009, 08:02 PM

Hmm, I've got the v3's and I haven't had any clunking. I'll have to take a look at this bolt/nut to see if mine are prone to the same problem you have.

Dangerlucas · 02-17-2009, 09:01 PM

Quote:

Originally Posted by Dangerlucas

Hmm, I've got the v3's and I haven't had any clunking. I'll have to take a look at this bolt/nut to see if mine are prone to the same problem you have.

I just check after I got home and while I can't really see the bolt with the wheels on I did feel around. It feels like I've got about 3-4mm of the bolt sticking out so there should be enough for it to grab and stay snug. Maybe I had a slightly longer bolt for some reason on the v3's the mount is thinner.

ssabripo · 02-17-2009, 09:04 PM

Quote:

Originally Posted by Dangerlucas

I just check after I got home and while I can't really see the bolt with the wheels on I did feel around. It feels like I've got about 3-4mm of the bolt sticking out so there should be enough for it to grab and stay snug. Maybe I had a slightly longer bolt for some reason on the v3's the mount is thinner.

which I think is correct. So either the V2's are incorrect, or I got a bad endlink somehow, or something is not right in my setup

arok · 02-19-2009, 01:26 PM

I'll dig in when I get home today.

ssabripo · 02-19-2009, 02:30 PM

Quote:

Originally Posted by arok

I'll dig in when I get home today.

thanks.!

also, if you could measure the length of your endlink screw (from where the threads actually start, not from the back)

AchtungF80 · 02-19-2009, 02:59 PM

Quote:

Originally Posted by Robert

Are you planning to inform KW v2 on this? I am putting off any suspension modifications with KW until there are more definitive answers.

KW Suspensions is a reputable company that makes quality products. I'm sure they will make it right. I and many people I know have ran KW Coilovers with no issues. I'm sure this is just an oversight on their part.

john08135i · 02-19-2009, 03:51 PM

Maybe when BMW fixed it the first time they replaced it with a non-standard part and nwo with the KW's it doesn't match up?

ssabripo · 02-19-2009, 05:21 PM

Quote:

Originally Posted by john08135i

Maybe when BMW fixed it the first time they replaced it with a non-standard part and nwo with the KW's it doesn't match up?

if that was the case, the other side would be good, which is not.

SamBoler · 02-24-2009, 09:15 PM

Shouldn't come loose as long as the installation was done properly but would like to see what happens with this

themyst · 02-24-2009, 09:45 PM

I had this problem on a few of my cars. Each time it was a bolt on the control arm that was loose due to improper tightening from the factory. Or it could be the horrible NYC roads.

ssabripo · 03-04-2009, 07:34 AM

****UPDATE*****
================================================== =====

I got this email back from Tom Edge, KW brand manager of north america, and looks like engineering in germany did recognize the issue after I sent them the pics, and will be sending out nuts with future kits:

Quote:

Shervin,

...We have decided to send out a 1mm shorter Nylock nut. As the locking material is inside the nut, rather than outside, it will grab the threads of the bolt...
...Expect to see the nuts shortly. Germany has been advised of the issue, and should be including the nuts for future shipments...

Tom

stovesax08 · 03-04-2009, 01:45 PM

Wow a company that recognizes an error and immediately fixes it (bmw are you paying attention?). Nice catch on all of this ssabripo. I'm suprised more people haven't responded to this thread. What happens to all of the people that already bought the V2's?

adrean8j · 03-04-2009, 02:00 PM

I wonder if this is an issue on the V1's.....

ssabripo · 03-04-2009, 03:28 PM

Quote:

Originally Posted by stovesax08

Wow a company that recognizes an error and immediately fixes it (bmw are you paying attention?). Nice catch on all of this ssabripo. I'm suprised more people haven't responded to this thread. What happens to all of the people that already bought the V2's?

more than likely the screw has not come lose.......YET

but it will eventually

02-14-2009, 12:06 PM	#1
ssabripo HALA MADRID! 939 Rep 2,879 Posts Drives: camels & donkeys Join Date: Jul 2005 Location: Plantation, Fl iTrader: (7)	clunking on front suspension...what could it be? a couple of months ago I had some bad clunking going on my front passenger side suspension, and after inspection at the dealer, it turned out to be a bad shock (strut assembly)....they went ahead and fixed it. fast forward, and a few days later I just said screw it and put some KW V2 coilovers, and all was well. About a week or so ago I started to hear a slight clunk again, on both sides but more pronounced on passenger side. it's not as bad (no multiple clunks as I go over a slight bump, just a single clunk) as before, but nonetheless it has been getting louder with time! I checked the top of the struts (3 bolts from engine bay), and they are tight. I checked the strut links, and seems tight. what else can I check? what can be causing this clunking? The coils are not even a month old, so no way this is a busted shock on the coil, is it? I mean, it's not like I went to the track or went over bad bumps! __________________ F87 M2 Competition, Sunset Orange, Exc, DCT. SOLD F80 M3 Mineral Grey/Sakir Orange, Exc, DCT... ED 6/2015 SOLDE90 M3, Interlagos Blue / M individual two-tone, ZCP, ZP2, ZCV, DCT, ED.
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02-15-2009, 12:36 AM	#2
morscode Got Boost? 52 Rep 601 Posts Drives: 19 x3 m40i Join Date: Nov 2006 Location: 818 iTrader: (3)	I would definitely say check the sway bars. My sway on the left side was OFF (nut missing), after I installed my coilovers and I always go over all the bolts twice at the end of the install. Narrow down when you hear the clunk. Bumps,speed during bumps, turns
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02-17-2009, 07:15 PM	#3
ssabripo HALA MADRID! 939 Rep 2,879 Posts Drives: camels & donkeys Join Date: Jul 2005 Location: Plantation, Fl iTrader: (7)	well I'll be damned! I think (keyword "think") I may have found an issue with KW coilovers for the 135i So today Technic and I went to his house and looked at the suspension and tried to make sure all the nuts were properly secured, etc. When we looked at the nut that connects the coilover shock arm to the endlink screw bracket, we saw that the screw was somewhat loose, but the problem is that when we tightened it, there wasn't much to play with.... so we looked at his car, and saw that the screw is much larger on the M3/335i, and it has enough clearance to stick out a good 1/2" so that the locking nut's teeth (the ones that actually LOCK into the screw) could get a grip. but it doesn't work that way on the 135i!! there isn't enough screw clearance for the nut's teeth to grap a hold of the screw: but in the M3, it does: after looking at it more closely, it seems that the link screw is definitely shorter, which means the the coilover arm should have been "thinner" than the ones for the 335i......they should have known this! So we tightened as much as we could, and put some lock gum, and so far, the clunk is gone!! I will ride it a few more days over bumps, but this is definitely either a luck thing, or we found a defect on the 135i's version of the KW V2!! __________________ F87 M2 Competition, Sunset Orange, Exc, DCT. SOLD F80 M3 Mineral Grey/Sakir Orange, Exc, DCT... ED 6/2015 SOLDE90 M3, Interlagos Blue / M individual two-tone, ZCP, ZP2, ZCV, DCT, ED.
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02-17-2009, 07:45 PM	#4
Robert Major General 417 Rep 6,968 Posts Drives: 135i -> is350 -> Tesla M3 perf Join Date: Aug 2005 Location: Socal iTrader: (1)	Are you planning to inform KW v2 on this? I am putting off any suspension modifications with KW until there are more definitive answers.
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02-17-2009, 08:02 PM	#5
Dangerlucas Captain 30 Rep 621 Posts Drives: BMW 135i Join Date: Jul 2008 Location: Bay Area, CA iTrader: (2) Garage List 2008 135i [5.50]	Hmm, I've got the v3's and I haven't had any clunking. I'll have to take a look at this bolt/nut to see if mine are prone to the same problem you have. __________________ Legal Disclaimer: Anything I or anyone else says about my vehicle on this website(1addicts.com or any affiliated or nonaffiliated sites), pertaining to modifications, is only to gain acceptance from my/our peers, and does not actually represent anything actually existing on my car, and thus, cannot be held against me in any issues, i.e. warranty claims, that may arise.
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02-19-2009, 01:26 PM	#8
arok Captain 46 Rep 987 Posts Drives: BMW F30 335i M-Sport Join Date: Jan 2009 Location: San Mateo, CA iTrader: (1)	I'll dig in when I get home today.
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02-19-2009, 03:51 PM	#11
john08135i Major 77 Rep 1,027 Posts Drives: 2013 M Sport, 2010 bmw S1000RR Join Date: Oct 2008 Location: Orlando iTrader: (0)	Maybe when BMW fixed it the first time they replaced it with a non-standard part and nwo with the KW's it doesn't match up?
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02-24-2009, 09:15 PM	#13
SamBoler Private First Class 6 Rep 178 Posts Drives: 2DR Join Date: Oct 2006 Location: LA,CA iTrader: (0)	Shouldn't come loose as long as the installation was done properly but would like to see what happens with this __________________ -Active Tune & Downpipes -KW V3 Coilovers
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02-24-2009, 09:45 PM	#14
themyst Major General 177 Rep 6,631 Posts Drives: '16 MK7 GTI Join Date: Feb 2009 Location: NYC iTrader: (8)	I had this problem on a few of my cars. Each time it was a bolt on the control arm that was loose due to improper tightening from the factory. Or it could be the horrible NYC roads. __________________ E90 LCI N54 6AT
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03-04-2009, 01:45 PM	#16
stovesax08 Second Lieutenant 7 Rep 269 Posts Drives: 135i, X5 45e Join Date: Feb 2008 iTrader: (0)	Wow a company that recognizes an error and immediately fixes it (bmw are you paying attention?). Nice catch on all of this ssabripo. I'm suprised more people haven't responded to this thread. What happens to all of the people that already bought the V2's? __________________ 135i Coupe-Manual, Montego, Lemon, HG Black, sport, premium, CA, HiFi, Ipod/USB, heated seats
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