In June, I installed an NM rear sway bar on my CM S ALL4 (2013 with ~78K miles). It's a great bang-for-the-buck upgrade. Since the installation, I get a light metal-on-metal tap from the right rear. It happens most at low speed and on small bumps. I thought is was likely one of three things: end links, sway bar bracket, or subframe. I've gone over the installation a couple of times making sure everything is torqued to spec. In the case of the end links, I replaced them in August as part of trying to find the noise. They are torqued higher than spec as suggested by Jerry at NM. In July, I installed KW V2 coilovers and SPC adjustable lower control arms (which I mention so that you know my setup -- the noise began before they were installed).

Here are some things I'm thinking about as possible causes. I'd appreciate any feedback.

1. Subframe. Is there a dampener or thin bushing that goes between the subframe and the unibody? I don't see it on RealOEM but their diagrams sometimes omit such things.

2. Rear diff mount bushings. Maybe the installation or changes to suspension stressed them.

3. Rear control arm bushings. The lower control arms are new SPC adjustable units but the uppers are original to the car.

Anything I'm missing? The car handles like a go-kart now but the noise is annoying. Thanks.

 

So it's been a long time since we owned an R60 (had a 2011 and 2014, now on our 2nd F60) and I have zero knowledge about suspensions, but I do recall a weird issue in which there was a tapping sound coming from the upper right rear. For us, it was the flap on the drain tube in the upper right rear of the open hatch area. A little tube with a flap on it. Removed the flap and the problem was solved. No idea if this is your issue but thought it would be worth mentioning.

 

Thanks for your reply, I appreciate it. I looked in the hatch area and saw the drain on the upper right but there was no flap, just a grommet. Nothing that could make the noise I'm hearing. It sounds to me like it's coming from a bit further forward than that area but at this point I'll look for any possibility.

Today I checked the rear diff mount and don't think that's the source. It also doesn't seem that the subframe is the cause. The subframe doesn't seem to have any movement (when I checked with a pry bar). The diff mount moves a little but that seems normal given the large bushings (which seem in good condition). Still at a loss.

 

Check the rear sway bar bushings. My 2011 developed a similar noise a couple of years ago and replacing them eliminated the noise.

 

Thanks for the reply. The bushings are new since I installed the NM sway bar in June. I hope the bushings aren't bad already.

I live in a smallish city and wasn't aware of a shop I would trust to take a look at this. But I finally found a place across the border in Minnesota. I'm tired of looking for the source. Will report back after they look at it next week.

 

My R60 does this too! (except left rear! - drivers side)
New endlinks installed this summer, new purple poly bushings too at the time.
I did have a period where I was getting a creeking sound over bumps and that was due to me not using enough grease on the swaybar bushings.

I was thinking it was a strut mount myself, I just replaced my front struts a month ago, and was going to replace my rears in the spring for good measure.


.tb_button {padding:1px;cursor:pointer;border-right: 1px solid #8b8b8b;border-left: 1px solid #FFF;border-bottom: 1px solid #fff;}.tb_button.hover {borer:2px outset #def; background-color: #f8f8f8 !important;}.ws_toolbar {z-index:100000} .ws_toolbar .ws_tb_btn {cursor:pointer;border:1px solid #555;padding:3px} .tb_highlight{background-color:yellow} .tb_hide {visibility:hidden} .ws_toolbar img {padding:2px;margin:0px}

 

When I put the coilovers on, I replaced the front mounts but not the rear. Maybe that was a mistake. I did replace the damping washers (Mini's name for the large ring gaskets that go on the top of the mount). The mounts are just a hunk of metal - no moving parts and they weren't rusty but maybe they deflect a bit over time. Since I already have the appointment with shop, I'll see what they have to say but will keep the mounts in mind. Thanks for the tip.

BTW, today, the noise was almost non-existent. The high was in the upper 30s, much cooler than it has been. Maybe it's temperature-dependent.

 

I would normally say the opposite, as rubber gets harder and brittle with the cold.. but this is a mini.. so... ALL BETS ARE OFF!
Maybe its softer and its *almost* metal on metal but not enough?

Nothing surprises me anymore with my R60