Popping, Crunching and Creaking Noise
 

I'll try to be a descriptive as possible...

So I've had this issue even back when it was completely stock, but back then it was once a month in a steep driveway at an angle and it would make a small pop crunch creak sound in what sounds like the lower front corner of the car. I didn't think much of it and never bothered to go to a dealer about it.

As time has gone on it has gotten gradually worse. A year ago I installed Sportlines with Darren in Portland. All went perfect and we went through and double checked everything and nothing can be found loose.

The noise has continued to get worse. At this point I've heard a number of theories of strut bearings, blown shocks, bad end links, springs etc...

I decided to bite the bullet and go for some coilovers. Ordered a set of FA500 series with Swift upgrade and roller bearing upgrade. Everything is installed along with some SPC rear control arms for the camber and toe adjustment. Everything went perfectly. Took it for a test drive. The car rides much better on the FA500 than the sportlines. So far I think the FAs will be a great investment once i get the alignment sorted out. I do have an alignment scheduled for Thursday to sort that out. But the popping, crunching sound is still there exactly as it was before the install. I have adjusted the endlinks to max length under load and shortest length under load. No change. Didn't seem to make a difference so i'm thinking it's nothing connected with the sway or end links. The sound is definitely noticeable even with a moderate music playing i hear it. I don't FEEL anything in the steering when the popping occurs. and after almost 2 years i have not gotten used to it. I need to find an answer.

Just so we are clear it started out only obvious with slow moving turns with inclines or speedbumps. Now it happens with any subtle suspension compression even while going straight down the road over small rough patches of road. Turning the wheel while parked makes no noise whats so ever. If i'm pushing the car hard around a corner there is no noise.

With the coilovers i have replaced shocks, springs, upper strut bearings and end links and the noise continues. I don't know what else there is besides tierods and the sway bar bushings. Anyone have any ideas? Thanks for your help.

I get the same sound, but I have a custom header/FI. I thought it was the undertray hitting the headers, but they did not find any dents anywhere. Its like metal hitting metal noise with a crunch.

Could it have something to do with the steering rack?

Edit: nvm

What about the bushings?

I think Andy from @Racecomp Engineering could help :)

I drove it one winter 2012 with a ton of red cinder all over the roads. Could cinder rocks get into some bushings? BTW, winter or summer seems to have no effect in the amount of popping crunch noise occurring. If that's all it ends up being, I'll gladly support our vendors. :) anyone else have any thoughts?

Im honestly taking a stab in the dark, Im no suspension geek like Andy though

Check your ball joint.

Double check if your front sway bar is dead-centered and its not hitting anything. Mine also had the pop when on slopes..it turns out my sway bar binds with control arm in the front.

I've tried adjusting the end links to the shortest and had the same noise. I also hand adjusted the endlinks until there was tension on both sides and had the same issue. But I never looked to see if it was centered. I'll take a look. Thanks.


Is it "Safe" to unhook the end links from the sway and drive a block to see if the issue persists? This could help me narrow it down.

You can take off the sway bar to better rule out if it is hitting anything.

I used to get the same in the front end. Thats stopped, but just the other day I got he same kind of noise coming from the rear suspension. In both cases it was the during the first warm snap after driving the car in winter. Not %100 sure, but I'm leaning towards maybe dry bushings binding up. Whats sad is I haven't had a ton of time looking under the car, so I don't even know if there is grease nipples or if they are the stupid no grease type.

Well I disconnected the sway this morning and the same noise continues. I'm at a loss. A friend of mine suggested maybe something loose on the subframe? Is that a bit of a stretch? Anyone have a diagram or pics of the subframe bolts? and torque specs would be great.

Quoting for visibility.

-alex

Ball joint... is the connection of the control arm to the tie rod? If not, can someone post a picture and/or description. And what should I be looking for? All of the rubber boots seem good. Thanks for the help!

https://www.google.com/search?q=ball...3Aft86club.com

See all the previous posts about this.

As for what it looks like... it's the part where your front LCA meets the spindle assembly.

-alex