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D3 - Axles, Brakes, Suspension and Steering Brakes, Springs, shocks, steering racks, steering columns, suspension arms, wheel hubs etc.

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Old 1st March 2020, 01:43 PM
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Johnmed Johnmed is offline
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Default Clunk from front suspension (maddening)

Hi all.

I have a faint clunk from the N/S/F wheel area at slow speeds. I trial fitted a replacement ARB from our sponsors. This made no difference.

Needing the car for commuting and work itself I have called in at a few garages, who’ve been too busy to get the thing on the lift. One garage mechanic said it would be the droplinks.

I removed the anti rollbar droplinks (that I replaced a while back) and without the ARB connected the noise was gone.

I though ahaaa! It could be the droplinks. I replaced them with some Lemforders from ECPs, and crossed my fingers.

The noise returned!!!!

Could the issue be the bushes on the ARB, (which look like new) or something else?

Could the ARB and droplinks just be connected to the problem?


I’m stumped.
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Old 1st March 2020, 07:29 PM
Joe2.0E Joe2.0E is offline
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Based on your description, I think it may well be the ARB bushes.
I put big miles on my 04 D3 when I had it and the ARB had to be replaced at one point as the bushes weren’t available on their own.
They were only available from Audi with the complete ARB.
Drop Links were replaced at least 3 times as they barely lasted 50 - 60 K miles but they relatively cheap and quick/easy to fit.
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Old 1st March 2020, 07:38 PM
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Thanks for your input Joe. I’ve ordered some Powerflex bushes. So we’ll see if they make an improvement. I’m on 170k+ now, so things will wear out.
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Old 1st March 2020, 07:48 PM
Joe2.0E Joe2.0E is offline
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You’re welcome. I’d say I was at 200K miles when I had to replace the ARB.
I think the bushes are bonded/glued to the original ARB.
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Old 1st March 2020, 09:23 PM
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That’s how Audi sell them Joe. You’re right. I have read of people, (I think in the US) over the years having success renewing the bushes alone.

I’m sceptical. But we live and learn!
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Old 7th March 2020, 03:23 PM
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Update:

Powerflex bushes were incorrect fitment. Got some Febest, fitted them with new droplinks, and took the undertray off (for good). Clunks and squeaks gone. Drives like a different car.

AT LAST.

My mild male autism can now find something else to be obsessed and maddened with!
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Old 7th March 2020, 03:39 PM
MikkiJayne MikkiJayne is offline
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Glad you sorted it. Have you noticed any difference in noise levels on the motorway? I find the tray makes quite a difference on both my A4 and A6, but I've never run an 8 without one.
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Old 7th March 2020, 03:44 PM
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Thanks. I’ve only driven the car locally Michaela. I am/was a tad concerned about noise levels myself. From what I’ve read it affects noise levels outside the vehicle mainly. Around town I can’t perceive any difference. Slightly surprisingly.

I’ll be on the M’way Monday. If the noise levels are of note I’ll update the thread.
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Old 7th March 2020, 06:55 PM
Joe2.0E Joe2.0E is offline
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Well done, thats a great result.
It might be worth posting the details of the correct replacement bushings.
Makes way more sense to buy 2 bushings rather than a complete anti roll bar.
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Old 8th March 2020, 08:58 PM
irelandbuyer irelandbuyer is offline
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John, thanks for posting up your findings.

I have a possibly similar issue. When the car is cold, the front is crunching. This goes away after I drive for a few miles. I read somewhere else that it's the bushings all right.

I had the car (D3 3.2fsi quattro) in with Audi for a few other things recently. They did a health check and recommended that the control arms and banana arms be replaced.

Here's the part numbers and prices:

Front suspension replacement control arms top £143.00 x2.
Bottom 224.00 x2 (per side) 4E0407505E, 4E0407693N.

Front suspension replacement banana arms £440.00 per side. 4E0 407 253Q


What's interesting is that the car flew through the MOT and my mechanic's view was that if there was a serious problem with the suspension, it wouldn't have passed...

Based on the OEM prices, we're looking at something in the order of c.£1500 to replace all the parts.

Would be great if you can keep us posted on how you get on. I'm wondering if just replacing the bushings should sort out this problem...

best regards.....
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