850 Crazy Noise & Steering Response

bobgrice · Post by **bobgrice** » 13 Feb 2011, 06:35

Hello all and thank you in advance for any suggestions. At wits end here.

1996 855R. 155,000 mi. Well-maintained by me since 75,000. New front suspension/steering noise. *Loud* clunk in parking lot maneuvers at full-lock (or near full). Also, feel clunk in steering wheel. Almost feels like entire front end is moving. It feels like geometry changes momentarily when noise occurs.

Here's what I have:
Bilstein HD's, installed about six years ago
Stock springs
IPD HD Sway Bars, installed about four years ago, maybe five

The following was replaced approximately [i]one year ago[/i] (probably about 10,000 miles ago):
IPD HD end links
IPD HD Spring Seats
Strut Mounts (either from IPD or FCP - I can't recall)
IPD Cheap-o Lower Control Arms (replaced [u]yesterday[/u] with OEM units)
FCP Remanufactured Axles (no idea of brand)
Outer Tie Rod Ends (don't recall whether OEM or aftermarket from FCP)
IPD Transmission Mount (with blue poly installed)
OEM Upper Torque Arm Mount (Firewall Side)
IPD Blue Poly Upper Torque Arm Mount (Engine Side)

The following was replaced approximately one month ago when I had engine and transmission out for blown head gasket and decided to go through the motor with all new seals, vacuum lines, etc. ([b][u]car was not making this noise until last few days[/u][/b]):
OEM Hydraulic Side Motor Mounts
OEM Front Motor Mount

I try to follow OEM procedures and torque recommendations, including installing new control arms using ride-height torquing.

Noise is persistent and sounds and feels very ominous. The front suspension is fairly simple, in my eyes, and I cannot locate where the problem could be. Strut-to-spindle bolts are tight. Ball joint is fully-seated in spindle. Top of strut does not rotate, indicating spring seat issue.

My thoughts are going to either a steering rack issue or bad axle(s). There has been a slight leak in the power steering system for a long time, but I keep the system full of fluid. I have checked the steering rack mount bolts and they are tight (this was my first guess). I had a helluva time getting the driver's side axle out for the engine removal, and, although they are only around one year old, they are re-manufactured and I'll admit to buying the ~$120 set from IPD, so they were not what I'd call OEM, although exterior quality looked OK to me. So, I'm wondering if I have a major axle issue. There are no noises going down the road at speed or typical clicking that indicates bad CV joints. There are still some slight noises going over speed bumps and hitting potholes, which are all around me and I generally attribute them to having an older, stiff (R) car. I cannot help but think this is related to the engine out & in, since the noise was not at all present beforehand. I have been driving the car for approximately three weeks now since getting it running again and have about 350 miles on the powertrain reinstall.

So, what thoughts does the forum have? It's serious enough where I'm a bit apprehensive to even drive it a few miles around to get groceries, etc.

As always, any and all suggestions would be greatly appreciated!

bobgrice · Post by **bobgrice** » 13 Feb 2011, 07:31

I neglected to mention that all four sub-frame bushings were replaced one year ago, chasing down a different noise.

Post by **jimmy57** » 13 Feb 2011, 11:53

OK. Did the tie rod ends get removed and maybe put on reversed? The curve in end is offset forward to clear wheels at full lock.
Is the toe in adjusted correct and if wrong causing the wheel to pulled in too far on the steering stop pad on lower control arms?

Post by **vjaneczko** » 13 Feb 2011, 17:24

When you hear/feel the clunk, does it clunk only once as the car is turned full-lock, or is it a repeating clunk-clunk-clunk as you drive in a full-lock circle? I'm thinking that one clunk would mean suspension, repetitive clunks would mean drivetrain.

bobgrice · Post by **bobgrice** » 13 Feb 2011, 18:20

Thanks, guys. It's definitely not the tie rod ends.

I did some further testing today and I get a persistent and consistent click (one per revolution) when the wheel is turned hard right. There is no noise when turned to full left lock. It's a rather loud click and you can definitely 'feel' it too.

As I mentioned, I had a tough time getting that driver's side axle out of the transmission and probably damaged it in the process. I'll pick up a left side axle from Axles Unlimited here in Charlotte and throw it in there and see what happens. I'll hold off on the passenger axle for now. Fingers crossed...