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Front suspension noise solved

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35K views 19 replies 9 participants last post by  Zona Kona  
#1 ·
I am sure there are other causes of this, but my front suspension (ZX3) was very noisy and harsh over small cracks and bumps - more at very low speed. I didnot feel it in the wheel but it was definitely in the front end. It went away last summer and returned this winter. It even did this sometimes when the car rocked side to side over road irregularities. I checked all I could for tightness and only heard a small metallic noise in the rack when I went after everything with a rubber hammer. The tie rods and sway bar end links seemed tight and I tried all the other suggestions offered in this forum.

So I brought the car in for battery cable recall and told them about this. It had gotten bad enough for them to drive and see the problem. The dealer replaced both front struts and put meatier sway bar links on and it feels like a new car. If any of you have this problem, you might want to look in this direction. Personally, I feel it was the struts but enjoy having the newer design links.

My MT-5 5 speed transmission whines (even coasting in neutral) but they felt it was normal - it has done this from day 1. I plan on driving another one before the warranty is out.
Does anyone else with this tranny notice this. To me it seems like the backlash in the diff gears is incorrect.

Gary
 
#2 ·
Same problem here, I just brought mine in for the wheel bearing recall and battery cable re-call. They test drove it with me to hear the rattle which appears when over small sharp bumps at avery slow coasting speed.

He thought since it had a double-knock type sound that it wasn't struts that it had to be the links you mentioned. The bushings wear out and is fairly common. I am happy to be getting both sides replaced on monday along with new headlamp lenses which were leaking moisture.

I will post to verify that it was the problem and all that they replaced to fix the noise.

Warranty almost up! Get those little annoying things fixed while you can!

Tooky
2000 SE Zetec Sedan 5SPD
 
#3 ·
I had a nasty clunking sound in the front suspension for awhile. I got under the car several times and whacked the sway-bar endlinks and tie rod ends to no avail. It finally turned out to be the left front sway-bar endlink ($13, replaced under warranty), but now I'm pretty sure the right one if gone as well. *Sigh* This thing's going to nickle and dime me to death...
 
G
#4 ·
Was this covered under your warranty? I have this same problem and my service advisor told me that it wasn't covered because nothing was broken. They said it was a strut plate that needed lubrication and they wanted to charge me like $300 so I said NO Thanks! Oh, by the way I'm on my extended warranty, but it covers the suspension. Maybe its time to find a new dealer. Your comments would be helpful!!

Thanks!
Mike

Edit: And I had to pay $80 just for them to look at it... oh that made me mad!

[ 03-30-2003, 12:17 PM: Message edited by: Mikey ]
 
#5 ·
Well I dropped my car off this morning to have the work done. I'll let you guys know what happens and if it solves the problem.

I guess I can't complain too much about my FORD service, they encouraged me to let them know everything that was bothering me before the warranty was up. And I reminded them today that i'd like 'both' left and right sway bar links replaced and they said of course, they wouldn't want me to have to pay for the second one after the warranty is up. Who woulda thought one could get some good service hey?

I'll keep you updated!

Bob
2000 SE Zetec Sedan 5SPD
 
#6 ·
Just to update you guys, the sway bar links I had done yesterday cleared up the clunking from my front end when going over small bumps / approaches at a very slow speed.
Image


If your out of warranty I think the parts are real cheap to do yourself job or bring it in as it was only an hour or so of labor.
 
#12 ·
I think I have the same problem.
Image
I can reproduce the clunking/clatter in my right front suspension by just rocking the car side to side while it's parked. Would this be consistent with bad sway bar links? Anyways, I am not too thrilled about bringing it in to the dealer to get fixed. Has anyone done the replacement of these parts themselves? How difficult a task would it be?
 
#13 ·
The links don't look hard to replace at all. Take off your wheel - use jackstands to be safe! Remove the link and replace. You might need to jack under the sway bar to remove tension before removing the link form the sway bar and strut. You hold the end with an allen wrench (metric I bet) and the other end is a common hex nut.

Unlike you, I could not make my noise unless I drove it and it was horrible. Last summer it went away and returned in cold weather. As the dealer changed the struts too, I can't say for sure what the real fix was. They might have wanted to put the new/improved links on....they look alot beefier.

If your warranty is over, I would change the links and go from there. They are not too expensive from what I hear.
 
#14 ·
Two new sway bar links later and the suspension noise seems to be gone! A big thanks to all the helpful posts on this thread. The install was basically straightforward...all you really need is a 5mm allen key and a 15mm wrench (17mm wrench optional). Like other people have found, the hardest part seems to be getting the existing, rusty nuts off. Installation of the new parts was very easy. While the new links are more "beefy" than the old ones, they actually weigh about 1 oz. less (~6.5 vs ~7.5oz).
If anyone else plans to do this installation, you may want four new nuts - part number W520203-S (Nut M10 Hex FLNG P/).
 
#15 ·
Hey all,
I think my car is the latest victim to suffer this problem. Besides the problem with my suspension, I’m having a problem trying to duplicate it to show my dealer. According to gmzx3 the problem “went away last summer” so I think that’s why I’m having the trouble duplicating it (I'm in AZ). I took it to my dealer and they replaced these part numbers YS4Z-3078(9)-BA which I believe is the struts only. My ride now is smoother but the noise is still there especially at night. Help! Any clever words or advice I can mention to my dealer to get them to replace my sway bar links too? Thanks in advance,

the Dirt Brown Kona in Arizona
 
#16 ·
I think its time for me to do this repair. Lets bump this up for others.
 
#17 ·
Does YS4Z-5K484-AA fix the whole problem? What are the part numbers needed? Do I need (2) YS4Z-5K484-AA ?