Help me diagnose my suspension clunk

[thechromecoyote]

I've been chasing this clunk for awhile.

At stop or slow speeds when steering I hear an audible clunk/ shudder of the front suspension seemingly located on drivers side.

http://youtu.be/k9mKuWNKLL4

Following things have been installed without any change or improvement.

LCA bushings front and rear positions
Strut mounts
Strut bearings
All bolts in strut set up
All bolts in LCA setup
ECS subframe bolt fix

There doesn't seem to be any play in the steering rack, and the ball joint boots do not appear torn.

CV boots look in good condition, and rotate freely without noise.

EDIT video uploaded

 

[thechromecoyote]

Bump, added video to help

 

[TypeR_126]

I'm assuming the wheels are off the ground in this video? Since you're getting it in both directions I would think it's a clearance issue with something. Maybe the swaybar?

Is the suspension all stock?

 

[ViRtUaLheretic]

Put the front up on jacks, climb underneath, and have somebody else move the steering wheel to reproduce the noise and try to track down the issue.

 

[thechromecoyote]

I'm assuming the wheels are off the ground in this video? Since you're getting it in both directions I would think it's a clearance issue with something. Maybe the swaybar?

Is the suspension all stock?

The video is with the wheels on the ground and the suspension under load.

Nothing stock about it except front sway bar / end links.

New mounts (034), bearings, springs (h&r supersports), struts (koni yellows). LCAs (superpro), and all new bolts.

Already tightened the seay bar. It was loose after the initial install. So I know it's not that.

 

[thechromecoyote]

Put the front up on jacks, climb underneath, and have somebody else move the steering wheel to reproduce the noise and try to track down the issue.

I can only reproduce the issue when the vehicle suspension is under load. Not easy to do with someone under it, no?

 

[TypeR_126]

I'm amazed you can move the steering wheel that easily with the weight on the car on the front end. The subframe could be shifting, although that usually requires more force. I'd double check the steering rack brackets, make sure they're seated into the subframe properly and that both the top and bottom are fully engaged.

 

[thechromecoyote]

I'm amazed you can move the steering wheel that easily with the weight on the car on the front end. The subframe could be shifting, although that usually requires more force. I'd double check the steering rack brackets, make sure they're seated into the subframe properly and that both the top and bottom are fully engaged.

Well the engine was on, so power steering did most of the work I'm sure haha.

But that's a good suggestion. I'll try and get under the car tomorrow to check that those bolts are seated and torqued properly.

 

[kruegernaut]

OP I would check torque spec on all your subframe bolts, and +1 on steering rack like these guys are saying. On the drivers side the steering rack has protruding bushings that go into the subframe, make sure they are seated? Bently manual for 2006-2009 says 52ftlbs + 90 degree's for all 4 of the steering rack bolts as well as the 4 main subframe bolts and 2 outer LCA bolts, and also recommends they be replaced every time they are removed. Also are you familiar with the below mod? I have found it to be exceptional. A total PITA to install, but awesome for locking everything in place down there.

http://www.golfmk6.com/forums/showthread.php?t=48759

http://forums.vwvortex.com/showthre...t-Rigid-Subframe-Collar-Kits-(Front-amp-Rear)

http://www.tyrolsport.com/product_inst/TyrolSport DeadSet Installation Instruction.pdf