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Gringing/Clanging/Crunching noises from front end :( Mechanic could not find issue
Hey folks,
Own a Bora 4-motion and been having horrible troubles with noises from the front end. The noises range from grinding noises, to clanging to rotational banging. Sounds like a wheel is loose but it isn't. You can feel vibrations of it through the car and it's quite audible from outside the car. Seems to develop when the car heats up and only after about 10-15kms of driving.
It happens while turning, especially at slow speeds, it happens when the clutch is both engaged and disengaged, it happens when braking and it happens when the car is coasting but not under acceleration strangely. The only other times it seems to not happen is when the car is cold and/or is given a bit of a boot. I've had my mechanic look at it (not a VW specialist but a JDM tuner) and he can't identify the issue.
As a bit of a background of the car:
1) Front end parts have all been changed in the last 5,000kms. This includes the ball joints, wheel bearings, tie rod ends, sway bar links, discs, stub axles and the driveshafts were only just inspected and given a clean bill of health by a pro.
2) The car has had new coilovers installed before I bought it - should only have 20,000kms of wear on them.
3) I did swap in some Audi S3 Quattro suspension to test and the noise was still there. I thought that the audi struts may have been shot as the wreckers banged it hard with a hammer to get it out of the hub and well the bora is a much heavier car so it may not have been built for the weight of it.
4) I've had issues with dodgy aftermarket driveshafts that the previous owner fitted, and found out they were too short (poor manufacturing). This would result in the driveshaft basically undoing it's driveshaft nut and and the driveshaft would fling around in the hub. I eventually caught wind of what the problem was when I tightened the driveshaft nut incredibly hard and the pressure of the shorter driveshaft resulted in the end snapping off. After that I found genuine driveshafts (2nd hand), had them inspected and they are now fitted to the car
I read somewhere that a bad brake master cyclinder can cause some nasty grinding noises? The noise does seem more to arise when the car is braking but the pedal isn't spongy nor is the noise isolated to only when braking plus the car seems to brake fine. That being said, at one point all the fluid was drained as I had to change brake hoses and replace the bushes in the rear control arm. I drained it by lightly pushing the brake fluid while the hoses were off and I tried to replace the fluid the old fashioned way until I realised I needed to turn on the ABS pump and get rid of the air in the system. My mechanic did this for me.
Has anyone got any ideas? Desperate here! My cousin wants to buy the car and I would like to get rid of it now that I have a new car and a company car.
Appreciate any and every help here!
Own a Bora 4-motion and been having horrible troubles with noises from the front end. The noises range from grinding noises, to clanging to rotational banging. Sounds like a wheel is loose but it isn't. You can feel vibrations of it through the car and it's quite audible from outside the car. Seems to develop when the car heats up and only after about 10-15kms of driving.
It happens while turning, especially at slow speeds, it happens when the clutch is both engaged and disengaged, it happens when braking and it happens when the car is coasting but not under acceleration strangely. The only other times it seems to not happen is when the car is cold and/or is given a bit of a boot. I've had my mechanic look at it (not a VW specialist but a JDM tuner) and he can't identify the issue.
As a bit of a background of the car:
1) Front end parts have all been changed in the last 5,000kms. This includes the ball joints, wheel bearings, tie rod ends, sway bar links, discs, stub axles and the driveshafts were only just inspected and given a clean bill of health by a pro.
2) The car has had new coilovers installed before I bought it - should only have 20,000kms of wear on them.
3) I did swap in some Audi S3 Quattro suspension to test and the noise was still there. I thought that the audi struts may have been shot as the wreckers banged it hard with a hammer to get it out of the hub and well the bora is a much heavier car so it may not have been built for the weight of it.
4) I've had issues with dodgy aftermarket driveshafts that the previous owner fitted, and found out they were too short (poor manufacturing). This would result in the driveshaft basically undoing it's driveshaft nut and and the driveshaft would fling around in the hub. I eventually caught wind of what the problem was when I tightened the driveshaft nut incredibly hard and the pressure of the shorter driveshaft resulted in the end snapping off. After that I found genuine driveshafts (2nd hand), had them inspected and they are now fitted to the car
I read somewhere that a bad brake master cyclinder can cause some nasty grinding noises? The noise does seem more to arise when the car is braking but the pedal isn't spongy nor is the noise isolated to only when braking plus the car seems to brake fine. That being said, at one point all the fluid was drained as I had to change brake hoses and replace the bushes in the rear control arm. I drained it by lightly pushing the brake fluid while the hoses were off and I tried to replace the fluid the old fashioned way until I realised I needed to turn on the ABS pump and get rid of the air in the system. My mechanic did this for me.
Has anyone got any ideas? Desperate here! My cousin wants to buy the car and I would like to get rid of it now that I have a new car and a company car.
Appreciate any and every help here!
full of bills and I have no garage at the moment to do the work as I'm storing my parents stuff as they go through a divorce. 
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