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So just to update this: I tried loosening and tightening all endlinks, no difference. I talked to Bilstein customer support, who said I had about the right number of threads above the center nut, and that it was possible the popping was being caused by the spring rotating in place. Doesn't make much sense to me, since I would think I would get noise when turning the wheel rather than going straight. The noise isn't horrible and the car rides great, so I've given up on fixing this.
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