Knocking sound over bumps after installing coilovers - please help

[Polo_GTI]

Has anyone here experienced a knocking (kind of metal hitting metal sound) sound after installing their coilovers?

The sound is only coming from the front and happens over pot holes when the shock is fully extended or when driving over speed humps.

I believe it may be coming from the strut mount bolt in the engine bay.
When tightened hard, it reduced the noise slightly but it is still evident. It's very discerning as it's a brand new car.

If anyone knows of the problem and how I can fix it I'd be grateful.

[killingwithasmile]

i had a very similar sound to your discription, mainly over small bumps or when hitting bumps slowly. it happend to be the main top coilover bolt had become loose and was knocking against the strut top bearing. Not sure if that was what you were tightening? the large nut in the middle of your strut top, the threaded shaft has a socket head allen key, mine was 7mm.

[Polo_GTI]

i had a very similar sound to your discription, mainly over small bumps or when hitting bumps slowly. it happend to be the main top coilover bolt had become loose and was knocking against the strut top bearing. Not sure if that was what you were tightening? the large nut in the middle of your strut top, the threaded shaft has a socket head allen key, mine was 7mm.

Yes that's the one. The coilovers were installed by a suspension shop. When I complained about the noise he looked at the strut top nut and tightened it. But he didn't have the right tools I don't believe and he couldn't use a rattle gun as it doesn't fit. He used a clamp to keep the outside bolt from turning and I think he used the Alan key to tighten turning opposite to the clamp. Yes your right it is an Allen key thread in the centre of the nut.

He told me something along the lines that the KW Coilovers are designed wrong as the metal plate that pushes up against the strut top tower is a smaller diameter than the stock ones? I wish I was more technical to be able to explain it better.

I was just thinking, if it can't be tightened any more, is there anything else I could do to stop the noise? Rubber boot? Rubber washer?

[remy]

This page has some info that might help, I found it because my coilovers are making a few noises too:

Megan Racing

[Polo_GTI]

Awesome thanks for that remy. It's a great read.

Unfortunately it looks like that the noise is due to the top 17mm nut and I don't have the tools to be able to tighten it whilst keeping the spring from turning by using the hex (or Allen key). Neither did the suspension place actually which is why it is making noise.

From the pictures in the link a simple spanner can be used, but the KW setup has the screw buried within the pillow ball upper mount. I would need a spanner bent 90degrees or so to get in there and hold the nut so then I have access to the hex nut.
Sadly, you'd think a suspension place has these tools on hand !

[remy]

Something like this is probably what you need:

Volkswagen Golf IV 1.8T > Tools > Suspension > ES#2219682 Strut Nut Wrench - ECS010

There's an ECS group buy going on atm in the MK4 forums, so depending on how urgently you need the tool it might be a good chance for you to pick it up along with a few other things.

There's also a way to do it using a spark plug socket I think. Marty talks about it in the latest Mighty Car Mods "Budget Street Cred" episode where they do up that MK3 Golf. Fast forward to the bit where they talk about the JOM coilovers for the car...or watch the whole thing if you haven't seen it yet, it's a great episode !

Mighty Car Mods - Budget Street Cred (Season Finale) - YouTube

[Polo_GTI]

That's exactly what i'll need... Could it be purchased from Bunnings/Bursons/Autobarn maybe?

This is why i'll need it:


I'm not in a desperate hurry so I might check out the group buy.

[Polo_GTI]

Something like this is probably what you need:

Volkswagen Golf IV 1.8T > Tools > Suspension > ES#2219682 Strut Nut Wrench - ECS010

There's an ECS group buy going on atm in the MK4 forums, so depending on how urgently you need the tool it might be a good chance for you to pick it up along with a few other things.

There's also a way to do it using a spark plug socket I think. Marty talks about it in the latest Mighty Car Mods "Budget Street Cred" episode where they do up that MK3 Golf. Fast forward to the bit where they talk about the JOM coilovers for the car...or watch the whole thing if you haven't seen it yet, it's a great episode !

Mighty Car Mods - Budget Street Cred (Season Finale) - YouTube

Thanks heaps Rem, just watched the video. I might see if I can get the right spark plug socket.

Edit: I just checked and unfortunately I'm out of luck. I tried a 21mm spark plug socket and its too small
I don't think there is any bigger than 21mm so ill have to use a wrench

Awesome video btw lol

[remy]

Here's a how-to, half-way down the page he describes a few solutions to tackle the problem:

Strut, spring, mount, and bearing installation on mk4 Jetta, Golf, or New Beelte

[KillaWOT]

If your nearby Ringwood i can help.

[Polo_GTI]

You guys are great, thanks I think I know how to fix the issue now.
I just need to find out the correct size of the nut and buy the correct tools.

Thanks Killawot, I'm not far from there actually