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 but to no avail.

Thanks in advance.

[paintman]

If you're getting no joy on the Lotus forums your best bet is to contact Nitron, tell them the problem & ask for the solution.

[Lost_BMW]

I have the same issue with my car (E46 BMW) after a full Nitron kit replacement in November. It was a pro job by Perfect Touch on behalf of CA Automotive.

Clunk describes the sound/feel perfectly, in fact a word I have used to describe it. It happens - but at the rear only - on sunken drains, pot holes etc. but not sleeping policemen so I hope the dampers are OK. I admit it has been worrying me but I assumed it might be down to the bushes/top mounts and the utterly awful roads here, ruined this winter.

I will give both PT and Nitron a call on Monday.

[spend]

Springs too short? Jack the car up & see if the springs come off the seats in droop..

[jonamacg83]

I took the car down to Nitron and they disassembled the whole lot, tested each damper then reassembled it all again. Didn't make a jot of difference. I figured it might be the balljoints, so I tore the suspension to pieces, replaced all the balljoints and wishbone bushes, and I still have the noise. The theory being that the stiffer shocks might be causing more stress on the other components.

The only bits I haven't replaced are the rear toe links and front rod ends, but I will be doing these in the next couple of weeks. I would find it very odd that both these components would be making the same noise, but there is a slim chance. Personally I am convinced its the dampers themselves, but as soon as I have done the toelinks and rod ends I will go back to Nitron and have further words with them.