Suspension clunking after changing coilovers driving me mad!

[jonamacg83]

Hi all, I have fitted a Nitron Kit NTR one way to my Lotus Exige, and followed correct procedure, everything has been tightened to the correct torque levels as specified in the Lotus manual, I even cleaned up the threads with a wire brush to ensure they are torqued up correctly. All the relevant spacers are fitted and yet the suspension 'clunks' over each small pothole/manhole cover etc that I go over. What is more bizarre is that each corner does it, so its obviously something to do with the units themselves or indeed the way they are fitted/setup. I have fitted coilovers to cars before and never come across anything like this. The rideheight and damping is adjustable, the current damping is set to factory settings and I have messed about with the rideheight but it is in the right ballpark.

Someone suggested that it could well be that I have overtightened the joints at the top and bottom (I did do them up pretty tight after I initially fitted them with the correct 45Nm) of the coilovers and hence seizing the bushes/ball joints. I struggled away in the dark tonight after work and slackened them off and there is no improvement what so ever.

If anyone has any ideas they would be greatly appreciated. Its driving me nuts! I have tried all the Lotus forums I am a member of but to no avail.

Thanks in advance.

[jonamacg83]

The 'clunk' is a very solid, similar sound to the one you get with a worn steering rack or when a caliper is loose etc. What really puzzles me is the fact that it occurs on all 4 corners. I will get some pictures up asap.

[jonamacg83]

They are brand new, so I doubt its the rod ends. I tightened them up to 45Nm as stated in the Lotus manual, maybe that simply is not tight enough?

[jonamacg83]

Not much conflicting advice on the torque settings then! Definitely some preload on all the springs at full droop. Will get photos up as soon as, though its fairly snowy at the mo and don't fancy battling against the elements!

[jonamacg83]

My car is on 45k miles, so it could well be the case that it needs a hefty refresh, though I am surprised that I wouldn't have heard all the noises previously.

I can't imagine I have managed to stretch the bolts, as I was only using a 3/8 ratchet spanner to do them up.

[jonamacg83]

I have had a brief check - Pushed things around a bit with a pry bar to find some play but nothing is apparent. What baffles me is its the same noise on all four wheels, which was not there before, I can't see how the old shocks would have covered up the bangs previously.