Installed BC coilovers.. consistent popping noise
 

Hello all. Recently, I installed BC Racing BR series coilovers. They ride amazingly and achieve the perfect height I want for a daily. Only issue is that they pop (in the front) pretty consistently. I knew I needed lower ball joints so I replaced those today. Even after replacing those, I still hear the pop. It's pretty much all the time. Here's what I've looked at so far:

1. I've inspected the tightness of all the bolts relating to what I replace. Everything is at torque spec for the part (using the factory manual).

2. Adjusted front pre-load multiple times (recommended is around 5mm, and that's where it's at right now).

3. Tightened the collars on the coilovers as much as humanly possible.

Here's what I noticed:

1. the outter tie rod ends have a bit of seepage from the joint around the top of the rubber gromet. Could the issue be tie rod ends?

2. Even with the preload set to manufacturer recommend specification, the spring can still be twisted with relative ease and moved back and forth (very slightly) with a good bit of force.

The current situation is midly frustrating, any advice on what to do next would be greatly appreciated. Thanks for your time :)

The nuts that connect to the strut to the top hat...are they tight?

they seem to be. Now that you mentioned it, that's the one thing I haven't put a torque wrench on yet. I'll look at that.

check your front swaybar end links?

Yes. Even swapped them out for some brand new OEM sway bar links I had lying around. Still popping. I've adjusted preload about 10 times at this point. I've torqued and retorqued the tophats/camber plates. I've even checked the subframe bolts, motor mount bolts, steering rack bolts, and it still hasn't fixed it. I've had a couple ideas thrown around that it might be the camber plates shifting since it's just metal on metal, but if they were shifting you'd be able to see marks on the body from that wouldn't you? Regardless, there are no marks from anything shifting. I've also tried adjusting the dampening with the adjusters on top of the coilovers, still nothing no matter what setting it's at. I'm very confused and I'm just looking for anything that could be causing it.

Also, it happens no matter the surface, no matter the angle of the wheel. Nothing seems to change it.

I wonder if it's your (or lack of) radial bearings. Look them up and what they do. Twist the spring and it might pop/hop/click as it turns seperate from the top hat. Radial bearings dismiss this. I'm just thinking out loud to try and come up with something that'll stick for you

Video is always helpful too. Can u replicate it turning the wheels while parked, or does it onloy happen w suspension travel

If you can, try oem top hats. Some plates are noisy, no matter if they are torqued correctly or not :(

What height?

Your OEM bar links may be hitting

If the top nut is tight then it could easily be play in the pillowball. Even a little bit of play will make a good amount of noise.