Clunking after installing H&R springs...Help

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#1
I installed H&R Sport springs on my Xi this weekend and it has a persistant clunking sound from the front end...it's not unbearable, just annoying, but I can feel it in the steering a bit too. It occurs mainly on moderately bumpy surfaces at all speeds. I've been told it's anything from the the strut mounts to the fact that the struts are "too long" now, as I did not replace the struts w/ the springs. So my question is, is there a way to remedy this w/o all new strusts at this time? If so, and parts are needed, what parts do I need? Also, if i left it in the condition that it's in right now, can I expect any damage? [bigcry]

Thanx in advance!!
 
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#3
Big Daddy said:
You need shorter struts and the constant bottoming out of the struts will damage them, I would replace them ASAP.
This brings me to my next question...I've talked with Koni, since they are the only ones who make a sport strut for Xi's, and they said their struts are made to OEM specs. This kinda makes me question if their struts are actually shorter...because I would run into the same problem at that point right?

I really wish I waited for coilovers now!!
 

Big Daddy

Senior Member
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#4
A good question for Koni, I think however what they are referring to is build quality, and that through the sdjustment procedure of the Koni Adjustables you over come the difference through valving. I am not an expert on this, but would not hesitate to call Koni and ask them.
 
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#5
Konis are made for a wide range of spring applications. I know the Konis for the E36 & RWD E46 have more travel than stock struts and will not bottom out with even lower springs than the sports. I assume the xi is the same, but could be different I guess.

At any rate, it obviously should not be making noise like that. Who installed the springs? One possiblilty is that the washers/bushings at the top are not installed correctly, or the top nut is not tight enough, leaving some slop in the assembly.
 
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#6
Hopefully as I write this up everyone can learn from it!!

So I went a head and took the afternoon off work to troubleshoot my clunking problem. I determined the cheapest course of action was to replace the strut mounts and go from there...off to BMW parts Dept. I go. $105 later I have 2 brand spanking new strut mount ready to install. Immediately upon taking apart the struts I compare the strut mounts and the old ones are bent, warped and general look used.

As I start putting every thing together I go ahead and check my sway bar end links as someone mentioned before...low and behold I find what i now believe was the cause of the clunking!!!!! The bottom drivers side sway bar endlink was loose as sh1t!!! I didn't even touch this connection through the entire build and rebuild until now. So moral of the story, check every connection even if you didn't mess with it before!!

BTW, the new strut mounts actually have made the suspension and steering more pleasurable and I recommend if you're at 60K miles, and you're a handy man, then take a look at them!!!

Thanks for the suggestions guys!!
 
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#7
I had the same thing happen. Put in new shocks/front sway bar and about a week later developed an annoying clunk. Found out it the top nut on the swaybar link to the strut was loose.
 


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