I'm labeling this post as a hail mary attempt. I have a 2012 FWD R60 that I bought for something to work on. I rebuilt the engine, completely rebuilt the front suspension (ball joints, wishbones and bushings, sway bar bushings and end links, new B4 shocks. In the rear, completely rebuilt the suspension. New wishbones, new NM 22mm swaybar, new end links, new shocks and mounting hardware and new springs as well as new trailing arm brackets with bushings. I've been chasing a noise in the back that really sounded like it was suspension related. However, I can rule that out now. The noise persists. I've checked the rear bumper, plate, plate lights, exhaust, shields, tank EVAP parts, removed the rear hatch plastic, adjusted the rear latch, chased a noise from the vent flaps behind the bumper that let pressure out of the cabin, used a rubber mallet everywhere, checked for a flap on the rear sunroof drain, installed temporary shims in the rear sunroof that had a rattle when you thumped it, inspected seats and seat belt tensioners, removed the parcel shelf and storage cover. I've covered everything I can think of and then some. It only happens when driving the car on a bumpy road, its in the back and I still can't tell if it's in the car or under the car. I'm asking here just in case someone has gone through this and tried something I haven't thought of. I cannot reproduce the noise by bouncing the car. It also is not the bottom shock bolt that can strip. Mine are torqued correctly.

I never give up but unfortunately for me that can lead to obsession. I just bought a car ear tool where you can place acoustical sensors in various places to try and pinpoint the sound. If you've read this far, thank you.

 

Hail Mary indeed ... Good luck. When you're done with your car, and need something else to work on, my 2014 has a couple of rattles that also only happen when going over bumps and there are also creaks in the dash area in colder weather. Perhaps you and the car ear could take a look / listen ..? 😉

 

I appreciate the tenacity to find the root cause... I once stripped a 2013 FWD R60 to its shell, so just because you didn't call it out specifically:
- rear tail light cluster has 4 mounting clamps, all engaged?
- rear tail light cluster plastic bulb holder snapped in place
- fuel fill door lock solenoid to frame mount
- previous fuel pump/filter replacement left a part in the fuel tank
- if configured with the rear bench option, ceiling seat belt reel mounts with two bolts to roof

Sounds like you need to find a road where you can reproduce the noise, bribe a friend to drive and you hang out in the back to pinpoint the noise location. Maybe even remove the rear seats/bench to give you more room as you go up and down the bumpy road a dozen times.

I am curious about this "car ear tool". Who makes it?

 

I have a 2011 R60. I read your post and a better description of the noise would help. Like you, I have replaced shocks, struts, mounting plates. Unlike you, I have NOT replaced all bushings, but HAVE replaced some suspension components. That said...

My R60 has a minor noise, which seems to emanate from the rear that sounds like metal-on-metal worn suspension parts (ball joints, etc.). It's pretty minor, so I'm kind of waiting for it to get worse. Is this the sound you have?

Like you, I have physically inspected, tugged, pushed and pulled on the rear suspension components to no avail. What I have NOT done is remove everything from the trunk area (would-be-spare-tire area). Have you done this?

D