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.

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.

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.

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.

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!

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!

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.

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.

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.

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.....

It’s something you could try, for little money and rule out. This was my thoughts too. Never had an advisory re: suspension, and my mechanic friend has given it the once over, as did an Indy a couple of years back.

The Febest bushes were £45 on eBay. Droplinks are cheap enough. All easy to replace. You need splines, M12 or 14 from memory for the ARB.

When I disconnected my ARB from the droplinks and rotated it in place, you could hear the creak I’ve come to know well. Especially in the colder months.

Re: the noise without the undertray. At all speeds it’s not noticeably different. Surprising given the TDi lump.

Without the tray, my front wheelarch liners blow into the tyres at speed, sadly they are a bit worn/damaged by this.

This was my concern too. I’m keeping an eye on them, and have secured them as best I could.

I recently bought these as had some knocking on the front:

4X MEYLE HD CONTROL ARM

1160500042/HD
1160500015/HD
1160500063/HD
1160500016/HD

Great piece of kit!

I have done all my upper and lower front arms. Still got this noise you describe when cold over speed bumps. Anti roll bar next then I think...?

Spray the bushes with WD40, if the noise stops before it evaporates, you know it’s the bushes. I’d put money on it being them TBH.

These were the bushes I fitted. Obviously specific to the diameter of the fitted ARB.

https://rover.ebay.com/rover/0/0/0?m...2F402110953874

I removed all the remnants of the bonded bush from the ARB before fitting.

I’ve read of this lasting for a good long while, but if it doesn’t I’ll buy the OEM bonded ARB from Audi.


Update 2 on the noise levels re: undertray, I’ve noticed a slight increase/change of noise in heavy traffic. Nothing major.

Link to AudiWorld thread I found:

https://www.audiworld.com/forums/a8-...iment-2932568/

Seems in the US the parts are $5, and if you search eBay for ‘ Febi part number 10023’ you can find them for under a tenner for 2!

Although the listings don’t state they are compatible with the D3.

OP of that thread reports 2 years use without issue.

useful info johnmed+++ did you buy these bushes to fit on a standard diameter ARB or the thicker sport one?

Mine’s standard.