What's up with the spindles?
 

I have never been comfortable with the idea of simply re-torquing the spindle nuts to solve the rear axle click.

To my mechanically-inclined friends, doesn't it seem like the actual issue is that the manufacturing tolerances for the splines were too loose?

Has anyone seen this issue on other platforms?

To those who have experienced the click, did the re-torque actually solve the issue, or does it eventually come loose again?

Hey, @Ultramaroon, I'm probably not the guy you wanted a reply from because I'm not familiar with the issue, but I'm curious about the sound, it's cause, and whatever you come up with to address it. My rear end (well, you understand what I'm saying...) is quiet, without any clicking whatsoever that I've heard, although my short ring and pinion, clutch-type LSD, and bushings create and transmit a lot of gear whine.

What exactly does the clicking sound like and when does it do it? Is it apparent under acceleration or deceleration, and only when going straight or around corners? If you suspect excessive tolerence in the splines on the halfshaft, my guess is that it's evident at low speed when you lightly go on and off the throttle - meaning the transition between the driveline being under torque from the engine and where the driveline is under torque the opposite way from the resistance caused by the rear wheels under deceleration. If so, are you sure it's caused by the halfshafts and not the differential itself? I had a BMW E46 M3 that suffered from the 'clunk' in exactly those circumstances, and it was caused by the differential. It was a known issue on those cars, exhibited by most them, and thought to be normal - but it sure seemed excessive to me. My FR-S does a similar thing, but it's so minor it's almost imperceptible. If I'm all wrong, you have my apologies in advance!

I've never heard it in person nor do I have it. I'm helping another member troubleshoot a single loud glassy "tick" that he gets when stepping on the gas in first or second.

Of course I want to hear from you. :)

I've just been bugged by this accepted fix ever since first reading about it. Today I figured "What the hell, maybe it's a good topic for discussion."

I don't get a tick while driving, but if i have the car in the air and i'm taking the rear wheels off, when i rotate the rear right wheel, it makes a click/tick, but my left side does not. I've early heard this sound with the car in the air, never heard it while driving. Thought it was strange, but everything performs fine.

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I bet you have some shit in your drum. That can be tough to track down too.

More speculation here.
http://www.ft86club.com/forums/showthread.php?t=92971

How can a spindle nut go bad?
@Hyper4mance2k captured it perfectly here. @rice_classic later asked the same questions as I now.

In that IWSTI thread there is discussion about greasing the splines. Also, it reappears for some people.

This reinforces my theory about manufacturing tolerance of the mating splines. Precision costs money.

Drum as in the hub? It was taken apart along with the suspension to replace studs and the sound is still there. It clearly has to be something making that sound, but it has yet to be a problem. I'll be checking axles just to be sure.

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A less likely source for the noise could also be some shit on the wheel speed encoder. It's magnetized. That would be a really faint noise. Try spinning the wheel with the sensor lifted.

I wonder if the fit between the hub and spindle changes with orientation. Splines fit a little differently relative to each other... Find the tightest fit?

I've never tried that with a splined shaft. I've always just put it together the first way it fit.

I'll have to check that out too, didn't think about that.

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I'm just spitballing. Worth a shot.