The title says it all. After my Koni SA's were installed, by a professional shop, and an alignment was done, there is now some loud popping when going over slower bumps and some turns. The popping/snapping mainly comes from the drivers front side strut, and ocassionally from the passengers rear side.

I assume this is not normal and they probably didn't set the lock washers properly or something. I have no luck with suspension, when I had my jeep lifted, I had to re-tighten the shocks every week or so because they kept coming loose.

Or, is it just settling in?

Its obviously the weekend so I cannot take it back until Monday morning. Any ideas???

Having just done the Koni install, I can make a guess as to the source of the popping. I'd guess that the upper spring seat is not indexed to the top of the spring or the rubber that sits between the spring and the seat was left out. The spring seat has an indentation that should match up to the top coil of the spring. Since checking this requires the strut to be removed and then requires a spring compressor to disassemble and check, I'd take it back to the shop.

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I'm guessing the mechanic installed the small retainer washer that holds the bump stop on upside down, the bump stop is thus rattling up and down......take it back......

>I'm guessing the mechanic installed the small retainer washer that holds the bump stop on upside down, the bump stop is thus rattling up and down......take it back......


Yah, or, they may have forgot to put in that washer entirely...
Are those coils progressive rate or linear rate?

I gotta feeling that there is some play between the top spring hat
and the mount.

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Thanks for the input guys. I'll take it back tomorrow. I had a quick look at both sides, everything seems very secure and installed properly from what I can tell but I don't weigh 2500 lbs like the car does so I guess me tugging on it is not much help. I'll post results as I find them out tomorrow to Tuesday.

Additionally, he could have left out the top washer that goes under the strut bolt. If left out the nut will seat but there will be play in the shock shaft.

Bottom line: I have checked this and the other suggestions on my car with Koni's and H-Sports and they still pop. I think that it is in the shock.

Do the KW's pop? Those are Koni's under stainless shell, correct?

OK, everything is perfect now. The Ball Joint was a bit loose, apparently he only torqued it to 60lbs which was causing the popping initially. Today, the poppingturned into an occasional more severe pop, with some bump steer. When I accelerated, the car would shift the steering to the right, when I let off, it would go back to the left. So, I dropped by the mechanic again and he immediately fixed the problem with a quick tightening of the ball joint on the drivers front side.

All is now good and well. I'll give a performance update on Sunday after the autocross event but she seems to be handling like a cheetah!!!