Front end "clunking"

[mckeand13]

I've posted on subaruoutback.org but received no relevant replies. Just looking for a little help here.

 

Problem:

I just replaced the struts and strut mounts on my '01 OBW 2.5L at 115K miles. There was a lot of suspension noise before hand which I attributed to the struts and mounts. Everything related to that is tight and has been reviewed.

 

A lot of the noise is now gone, but there are still plenty of annoying noises especially at low speeds. Most of the noised come from shallow potholes and cracks in the road while under 30mph. It sounds like all of the noise is coming from the front end.

 

Later on......

 

I think I may have found the source of my low speed "clunking" from the front end.

 

I pulled the wheels off today and checked lower ball joints and then inner and outer tie rod ends. It's actually hard to tell if the the tie rod ends have any slop, but I couldn't notice any by sight or with my finger on both parts.

 

Put the tires back on for leverage over just holding the rotor and caliper. I could hear a lot of loud knocking when I grabbed the front and back of the tires and quickly pushed in and out.

 

That led me to the steering rack. It looks like the large geared shaft has some vertical slop as the tie rod moves it back and forth. It seems like it should have purely axial movement. I'm not sure if it's that vertical slop, or the engagement with the gear driving the shaft.

 

Why does mine have a bunch of slop and knocking emanating from it?

 

Check out this video I posted. You can hear it!

 

 

I noticed in the factory manual, there is reference to adjusting a "preload" type of nut. It basically adjusts spring tension on another piece that is being forced into the rack shaft. I'm not sure if it is just pushing the rack against another bearing surface or what it's intent is. The manual states to tighten it to a certain torque and then back off 25deg. I can check this, but what does it really do inside the rack? If it were not adjusted properly, could it contribute to movement causing some clunking?

 

Any help or suggestions welcome.

 

Thanks.

[Danbob99]

If there is movement when you move the tire top and bottom it is likely not the steering rack. Steering racks will show movement when the tire is moved side to side. It is more likely a wheel bearing or hub if you have top to bottom wheel play.

 

I wouldn't go playing with the tension on the steering rack, if it has play in the gear drive, you should replace the rack. I'd be sure it is not play in the inner tie rod ends first though, this is fairly common.

 

I've also seen many issues with strut top nuts making noise after changing struts. They can be challenging to get fully tight when off the car. Easy enough to double check in the car, and a lot easier to get tight once installed.

 

Hope this helps. Let me know what you find!

 

Dan

[mckeand13]

No movement at all when grasping the tire at 12 and 6 o'clock.

 

A bunch of clunking when I grab it and 3 and 9 o'clock.

 

It's pretty hard to feel and see what is going on with the inner tie rod joint, but I can't detect any play in it.

 

Why do you suggest not checking/adjusting the rack? It's there for that specific purpose right?

 

Are there bushings at each end of the rack that wear?

[3Pin]

If you get stumped, I have had lots of subaru's worked on at Advance Auto in Milwaukee. They a single Mom and Pop kind of shop at 35th and state. Not fancy, but they get it done for a fair price. Good honest people. Ask for Tony 414-342-1047. They are working on a 96 outback for me now with a bad engine that I found for $500.

 

Best of luck to you.

[nickb21]

You might also want to check the 2 universal joints on the steering linkage. I think you can tighten them with an allen wrench.

 

I've got an '02 with a clunk as well and I think I narrowed it down to the front sway bar bushings. Try yanking on the bar in different directions and see if it makes any noise.

[Fairtax4me]

My initial though is bad sway bar bushings/end links. They tend to make a lot of clunk sounds when on fairly flat ground with only small bumps.

 

But after seeing the video, it looks like it could be the inner tie rod ends. Much more common than a bad steering rack. From what I understand Subaru steering racks rarely go bad. When they do it's usually due to abuse or accident damage.

 

You'll have hard time seeing play in the tie rod ends moving them by hand. You can get a helper to lightly kick the tire in each direction, not hard, just enough to reproduce the sound.

That or you can try using a rubber mallot and hitting the tire on each side (inner sidewall, from under the car) while also attempting to watch the joint for movement.

 

If there were play in the steering rack I would expect there to be a fair mount of play in the steering wheel as well. Much more so than what a tie rod end would produce.

Edited October 28, 2009 by Fairtax4me

[mckeand13]

I've checked the swaybar bushings and endlinks. All seems well there. Almost impossible to move at all by hand, and no noises as I jerked it around.

 

I'll see if I can round up a helper and check the inner tie rods again.

[idosubaru]

if it's that obvious it seems to me it needs to be looked at physically/on sight. hard for us not being able to see/touch it.

 

you could do the same thing yo'ure doing to this side, to the other side front wheel just to make sure it is indeed different.

 

i think you'll find htis quickly with a helper.

 

wheel bearing?

 

has the car ever been in an accident or something? all of these strut issues and now this...this sounds like more than nominal wear.

 

yes the rack has bushings on each side - two. very easy to replace. if they were bad you would notice it in the steering, like a slight delay or wandering more than noise (unless the bushings were completely gone but then you'd notice that). very unlikely on such a new car.

[mckeand13]

if it's that obvious it seems to me it needs to be looked at physically/on sight. hard for us not being able to see/touch it.

 

you could do the same thing yo'ure doing to this side, to the other side front wheel just to make sure it is indeed different.

 

i think you'll find htis quickly with a helper.

 

wheel bearing?

 

has the car ever been in an accident or something? all of these strut issues and now this...this sounds like more than nominal wear.

 

yes the rack has bushings on each side - two. very easy to replace. if they were bad you would notice it in the steering, like a slight delay or wandering more than noise (unless the bushings were completely gone but then you'd notice that). very unlikely on such a new car.

 

I got the car at about 83K miles. I haven't seen any indications that the car was ever in an accident, and no reports stated it was.

 

- How do I check the wheel bearing? I've checked for play while holding the hub/rotor at 12 and 6 and detected no play.

 

- How are the rack bushings replaced? I couldn't find them as parts in the service manual?

 

Thanks

Edited October 30, 2009 by mckeand13

[mckeand13]

I don't think this narrows it down at all, but today I tried something.

 

Car turned off, turn wheel back and forth a bit very quickly, and I get a bunch of clunking. To me, that still says it's either tie rod ends (inner our outer), or backlash in the steering rack.