R50/R53 :: Hatch Talk (2002-2006) Cooper (R50) and Cooper S (R53) hatchback discussion.

R50/53 Clunk... I go nuts!!

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Old Mar 24, 2021 | 03:40 PM
  #1  
aemkay's Avatar
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Clunk... I go nuts!!

Hi All,

I go nuts... I had my 06 R53 fronten apart twice, replaced everything with OEM or exceeding products (poly’d some stuff) that is a joint, engine mount, strut, whatsoever... 2nd subframe drop we even had the engine out to do major maintenance. still get a noise from the passenger side frontend when I go over wobbly road parts or even high street markings. It sounds a bit like something heavy bumps in the underbody/ subframe. I finally thought its the power steering pump as its close to the steering rack, nope... Any ideas from you guys?
 
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Old Mar 24, 2021 | 08:50 PM
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From: Conyers, Ga.
Originally Posted by aemkay
Hi All,

I go nuts... I had my 06 R53 fronten apart twice, replaced everything with OEM or exceeding products (poly’d some stuff) that is a joint, engine mount, strut, whatsoever... 2nd subframe drop we even had the engine out to do major maintenance. still get a noise from the passenger side frontend when I go over wobbly road parts or even high street markings. It sounds a bit like something heavy bumps in the underbody/ subframe. I finally thought its the power steering pump as its close to the steering rack, nope... Any ideas from you guys?
Have you checked the Control Arm bushing. The rubber OEM version wear out fairly quickly. I had to change mines out at 70k.
 
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Old Mar 25, 2021 | 07:10 AM
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Originally Posted by aemkay
Hi All,

I go nuts... I had my 06 R53 fronten apart twice, replaced everything with OEM or exceeding products (poly’d some stuff) that is a joint, engine mount, strut, whatsoever... 2nd subframe drop we even had the engine out to do major maintenance. still get a noise from the passenger side frontend when I go over wobbly road parts or even high street markings. It sounds a bit like something heavy bumps in the underbody/ subframe. I finally thought its the power steering pump as its close to the steering rack, nope... Any ideas from you guys?
Check swaybar bushing. The swaybar will rust out under the bushing. That's why I'm replacing my swaybar today.
 
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Old Mar 25, 2021 | 08:39 AM
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sounds like the damper is bad or the nut at the top of the damper is loose. I had this with my coil overs and it was absolutely the most annoying thing in the world. If you have stock shocks and springs, pull the black cap off the top of the strut and check to see if that nut is loose. If it is loose it will make a metallic knocking sound when you go over bumps.



 
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Old Mar 25, 2021 | 11:37 AM
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Yes, these are already replaced with poly bushings...
 
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Old Mar 25, 2021 | 11:38 AM
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Originally Posted by shrevemini
Check swaybar bushing. The swaybar will rust out under the bushing. That's why I'm replacing my swaybar today.
Swaybar bushings replaced with poly bushings adn we even double checked to have the right diameter...
 
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Old Mar 25, 2021 | 11:45 AM
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Originally Posted by Thought of a good one
sounds like the damper is bad or the nut at the top of the damper is loose. I had this with my coil overs and it was absolutely the most annoying thing in the world. If you have stock shocks and springs, pull the black cap off the top of the strut and check to see if that nut is loose. If it is loose it will make a metallic knocking sound when you go over bumps.

I did it several times but maybe there is something wrong there... good idea! the first replacement of all parts was done by the previous owner. looks like a good job but he was not a certified mechanic. I checked today and found even though the upper strut mounts look like new, the driver side (clunk is on passenger side I would say) the stut cap is higher up in reference to the shock tower "hole" than on the passenger side... so here we go, change that again.

i thought it could be the power steering pump wobbling against the steering, but I put a piece of foam in between yesterday and no change, that thats not it... Can anyone describe the "noise" a worn out inner balljoint makes? Thats the area I would say the noise is coming from and looking at the gaps between a-arm and subframe on both sides, there is a difference left to right. They are said to be new and look new, but maybe something went wrong during install or it is just a bad part from the factory
 
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Old Mar 25, 2021 | 01:42 PM
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Originally Posted by aemkay
I did it several times but maybe there is something wrong there... good idea! the first replacement of all parts was done by the previous owner. looks like a good job but he was not a certified mechanic. I checked today and found even though the upper strut mounts look like new, the driver side (clunk is on passenger side I would say) the stut cap is higher up in reference to the shock tower "hole" than on the passenger side... so here we go, change that again.
Your tower isn’t mushroomed, is it?
 
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Old Mar 25, 2021 | 02:02 PM
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My car used to knock/clunk on every change between forward and reverse. It ended up being the swaybar endlinks. They are stock and I torqued them to spec a few times, but the clunk remained. When torqued past spec it stopped. Maybe your endlinks are loose or bad. Mine will eventually be replaced with better aftermarket units.
 
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Old Mar 25, 2021 | 02:27 PM
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Like I said my swaybar bushing an swaybar itself were rusted an eaten up under the bushings.

 
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Old Mar 25, 2021 | 02:44 PM
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Originally Posted by RB-MINI
My car used to knock/clunk on every change between forward and reverse. It ended up being the swaybar endlinks. They are stock and I torqued them to spec a few times, but the clunk remained. When torqued past spec it stopped. Maybe your endlinks are loose or bad. Mine will eventually be replaced with better aftermarket units.
Mine where replaced too but I will check for sure, thanks!!
 
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Old Mar 25, 2021 | 02:46 PM
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Originally Posted by deepgrey
Your tower isn’t mushroomed, is it?
Not bad in any way and I have defender plates (cravenspeed) installed
 
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Old Mar 25, 2021 | 02:48 PM
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Originally Posted by shrevemini
Like I said my swaybar bushing an swaybar itself were rusted an eaten up under the bushings.
That looks bad... I am located in FL and my car has always been in FL, so there is literally no rust or corrosion anywhere (I love it!)...
 
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Old Mar 25, 2021 | 07:25 PM
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Can be anything suspension related. Bushings, ball joints, struts, mounts, sway bar, end links...

I ended up refreshing everything...pulled the subframe

replaced the wheel bearings also while I was at it

Now if I could just get ride of the interior trim noise...
 
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Old Mar 26, 2021 | 08:33 AM
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Originally Posted by ssoliman
Can be anything suspension related. Bushings, ball joints, struts, mounts, sway bar, end links...

I ended up refreshing everything...pulled the subframe

replaced the wheel bearings also while I was at it

Now if I could just get ride of the interior trim noise...

I hear ya... Been there, done that but one clunk remains... it is crazy but we will find it. The interior noise will never by zero i guess, to much plastic and a stiff suspension work against that "dream" I am afraid ;-)
 
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