So I followed the instructions to replace the front struts of my R56. Everything was back together and I took it for the test drive. In the neighborhood with new roads, it was very nice. As soon as I got on city streets, a minor bump will cause a loud clunk

I figured I missed something and went back and re-torqued all the bolts. I took it for another test drive, same thing. Hit a bump, get a clunk.

Any ideas here? I've got an appointment tomorrow at the garage for new tires and I'd really like to have this wrapped up before then.

 

All factory stuff?

The heavy washer has a chamfer on one side, that side must face the proper direction (toward the shop body, if I remember) to distribute the load properly. Make sure that you are confident with that part of the assembly.

The other thing that comes to mind is to make sure that the springs are in the seats properly.

Did you put the original top hats/strut bearings back in place? Is there any chance that one of those are bad?

Mike

 

The struts were OEM and I did reuse the springs. The springs appear to seated in their perches correctly. And I'm pretty confident that the washers were placed correctly as well. At this point I think I'm going to let them place the new tires and align the front tomorrow and ask them to replace all the bushings. If it still gives the thunk, then I'll take them all out again and verify the install.

 

Maybe this will help.
taken from a different forum



UPDATE:

I was getting a clunking noise, again, so after much inquiry a guy who installs many of these FSD's in MINI's (like hundreds?) and has a shop in SoCal said it could be the nut that holds the strut to the plate is working loose. He said to over torque it by 8lb. I did it and the noise vanished instantly. He also said that if it happens again to put some blue locktite on the threads and re-torque.

I do believe the guy knows what he is talking about. He is a proponent of Koni FSD's and did not try to sell me something else. So the big take away from this is over torque 8lb with Blue Locktite and all should be well with the MINI World
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I was going to suggest the strut top nut. I've had that problem on nearly every car I've owned.

 

Double check sway bar bushing and endlinks.

 

I tightened the top nut and then went on a test drive. The thunk is gone! Now I can get the new wheels and alignment this morning without having the garage fix my mistake. Thanks to everyone who posted!

 

I live in New Jersey, the roads are disgustingly terrible in Jersey, and have had this problem since I owned the car. I obviously never changed springs or went to coilovers or anything, but it's kind of annoying. Is this an easy fix or something I should take to the shop to do?

 

If you're still under warranty, I say go to the dealership. If not, it's pretty easy to do. From memory, I believe you need a 22 or 21 mm socket, a 6 mm hex wrench, and two pairs of vise-grip pliers. Place the socket over the top nut, lock the vise-grips on the socket. Then insert the hex wrench and secure the vise grips on it. Then hold the socket in place, then turn the hex wrench counter-clockwise. I think there is a link to this procedure somewhere here, but I haven't found it.

 

Cool, thank you.

 

This is good guide http://www.*********************/lib...cks-struts-68/

Or this. http://www.pelicanparts.com/techarti...eplacement.htm

Or this http://www.minicooperspeed.com/mini-...-installation/

We didn't need to take off the tie rod just the pitch bolts and end links. That was on an R 56. Good luck

 

http://www.minicooperspeed.com/mini-...-installation/ sorry about the first link, this is also a good guide