I brought the car to the dealer in mid july, right before my warranty expired, for a suspension clunk. They diagnosed it as worn sway links. The problem went away but now its back, and its the exact same clunk I hear going maybe 5 mph and only over "steep" bumps.

Normal driving speed, you dont feel or hear it, its really only going off idle that its pronounced.

Well heres a short clip

http://www.youtube.com/watch?v=E0LX8wZtj_s

I called the service dept and there is a 1 year warranty on the parts and labor, so would this be the sway links? Or the ball joints, which were done on September 27, 2010 (which is just out of the 1 year warranty)

Edit: and if I have the car stationary, and jump up and down on the strut tower, there is no noise. Its only when theres a "jolt"

Thanks, its really annoying

 

I honestly don't think its sway bar links, possible ball joints, thrush bushings.
But the sound is definitely coming from the front. I hope that your air struts aren't going bad.

 

Totally guessing here, but maybe with car being SO lowered (looks great BTW), as struts compress they are bottoming out somehow or hitting something. Curious if it makes the noise with it raised in Valet setting up high.

 

raised or lowered, its all the same - if not worse when its higher.

Its only a recent development, Ive been this low for awhile and no issues. Something is definitely loose, I just want it to be the sway links so I can cash in on the one year parts warranty.

So odds are it is not sway links, even though its replicating the same issue I originally brought it in for?

 

You really need to put your car up on a lift, then use a pry bar to check ball joints and bushings, suspension linkages, etc.

 

Ive looked under there and checked tightness of bolts, and banged on stuff, I cant even replicate it when the car isnt moving.

I guess i'll have to dig further. Still drives/handles fine, just clunks on bumps/driveways, etc.

 

You got me, I don't know what else to tell you.

 

Check your rear shocks (not the air units). They're probably leaking.

 

Its the front passenger side, though it does appear to be happening on the driver side every so often

 

Yeah I dont think that sound is from the ball joints, have you checked your upper control arms? It is definitely annoying. Please keep us posted on your findings.

 

did you figure it out

 

HA I'm not alone I have exactly the problem, and it drivesssssss me nuts. I went to dealer they test drove it, didn't find s**t. Pearlpower was looking at it, when we did the star lowering, he checked everything with pray bar and everything was tight. It only does it when Im going over the speed bump sideways or other uneven surface. Other day when it was raining though I think the clunk went away but not 100% sure. Also I never listened from the outside of the car.
I really, really hope somebody will be able to figure it out.

 

Take a look at the upper control arm.. If not take a look at the steering rack. Mine makes a little noise on speed bumps and going down the drive way time to time.. I had the upper control arms replaced and it seemed a bit better but the noise is back!

 

I have this same issue in the rear area when going over speed bumps. It's barely there if the car is in Sport2, but when it's in Comfort, it's very obvious.

 

Not fixed yet, have other/bigger problems now. It has gotten worse and now makes sounds on the driver side as well.

 

My new issue is the rear make a clunk noise when I accelerate from a stop :/ I think its the spindle bushing..

 

It sounds exactly the same as my old M5 when the shock retaining nut came off.

 

Here is the videos of my noise/clunk

http://www.youtube.com/watch?v=UgFJCJhzLfI

http://www.youtube.com/watch?v=HhnahAbMnJw

 

Im bumping this because its been nicer out lately so i've been trying to diagnose a few issues.

Like I said before, it doesnt clunk when stationary and jumping up and down n the strut tower. But today I was banging on the wheel/tire with my fist and I can hear it. So its a side to side issue, more so than an up and down.

What would this mean? Also, steering is a touch sloppy and can make a similar clunk sound if I turn the wheel back and forth fast enough.

 

Based on your original post, I'd try doing the sway bar end links again before anything else. If it's still there with new links on, you have eliminated them and can dig further as necessary.

As fyi, I have needed to replace the front sway bar end links about every 18 months (every 5K miles) on my E63, my noise is different than your video, but it clunks going over speed bumps or at end of driveway. Replacing the links cures it every time until it gradually comes back. Dealer replaced mine twice under warranty so far, going to have them done again next time I am in for service.

 

Dang! Alright.

I don't trust my dealer that much, and I am worried if i bring it in, they are going to find a way to dig into my wallet.

 

Disconnect both sway bar links before buying new parts. Loosen the nut holding the link to the sway bar, then remove the lower nut and pivot the link up. Zip tie it so its out of the way and go for a road test. While you are there, check the sway bar link balljoint for any signs of play. If all checks out then keep looking.

My guess would be that the upper sway bar link bolt is not torqued properly

 

http://youtu.be/OaKl6Pd1qQU

Car is jacked up on the other side, this wheel was on the ground.

 

Wow that video is kinda scary! Have you looked over your steering parts to make sure nothing is loose on there?

Can you get the front end up on jackstands and try to make the noise again? Send someone under there to look/listen and you'll find the culprit quick I bet. You can maybe have them grab and put some pressure on different components to see if the sound changes while under there as well to help diagnose it.

 

It was a one man show today, and tomorrow I will jack it up and take the wheel off to inspect.

Everything checks out visually, Im just trying to isolate the sound and go from there. The car rides/handles fine, its just the noise and maybe slight play side to side with the wheel off the ground.