Front right clunk, tie rod scrape marks. EDIT: FIXED! :D
 

See 2nd page for fix.

Long story short, it was the bolt I least Suspected.


ORIGINAL MESSAGE:
Okay first off. Here is my set up.

Tein Flex Z - lowered maybe 1.5" - stock sway bar endlinks
Enkei rpf1 17x9 35 w 245/40/17

Recently with the last week there as been a loud AF popping noise going over decent bumps in the road, speed bumps, and into the driveway.

I went through all the motions, lifted the car, torqued every suspension bolt to spec, did some greasing etc etc.

Popping still there. I did notice that on my tie rod there is some scrape marks and I am beginning to think it is smacking the over pipe on the passenger side.

I literally have no clue if that is the source or what, but it is a loud loud noise.

Any ideas? Really need help on this one.

Photo of scrape
https://scontent-sea1-1.xx.fbcdn.net...13800960_o.jpg

other than that white shit on your stab bushing, what am I looking at?

The front tie rod, steering rack or whatever. That big scrape on it is from it hitting the over pipe or something.

If that's your stock overpipe, yeah, I suspect a torn or loose engine mount.

Yikes. Wouldn't I feel that more though as opposed to just when I go over bumps?

Check your exhaust bolt hangar too.

But are you sure that mark isn't from the manufacturing of the aluminum steering rack housing?

I admit it's a stretch. (accidental pun) Are you sure those marks are fresh?
@Kostamojen also has a point that it may just be where the parting lines were cut away.

Defs seems looks like scraping and not something that was from manufacturing. Will be taking the car to a shop to have them look.

Weirdest part is the noise doesn't sound like two objects banging together but more of like a robots elbow getting dislocated if that makes sense haha.

Too bad we aren't in the same Vancouver. I'd help you check it out.

Take off your strut/coiliver whatever and see if you can move the knuckle up to a location that the tie rod collides with something. Maybe measure from the fender to the lugs so you know where it sits on the ground and start there? Check sway bar endlinks for binding too

Take a permanent marker and cover up the scrape, then see if it gets worn away again.

Not sure about the scrape, but mine clunks as well. I think it's just the sway bar bushings.


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My Flex Z's make a LOT of noise as well.. ill check to see if i have this scrape mark

Here is a sample of the noise. Whole way to work it didnt make it and then I hit one patch of road turning into the office and it did.
https://youtu.be/ygCEJ2zsHcM

Buddy of mine had a blown shock that sounded exactly the same. You said you checked all the heim joints already. What about worn stab bushings?

Stab Bushing?

I got an appointment Thursday at a shop so hopefully they can see what is up. Hoping nothing major.

Stabilizer bushing. Anti-sway bar bushing. That one on the right with all the crusty shit looks suspect but if it was knocking, all that stuff would've shaken off.

I had a similar clunk when then the center nut on top was loose. You may need a Allen wrench and a wrench that can open wide enough. Or an impact

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OH SNAP.

So. I am an idiot. I had the entire car apart the other day looking for the source of this. Retorqued every single bolt related to the suspension... except for the ones attaching the strut bars to the back of the firewall...

I don't know why I didn't bother to check these. Sure enough today, pulled in the driveway. CLUNK. Sat there in frustration, opened the hood and just happened to notice one of the bolts protruding out. Tightened all 4 back bolts to spec. Got in the car, sped over a shit ton of bumps and speed bumps. No noise :D

Such relief. Gonna need a beer. Thanks for all the suggestions. Still need to monitor why the tie rod has scrapes on it though...

Cuz you scraped it duh