http://www.threeringranch.org/norm/suby.htm

'05 WRX wagon w/ Tein Flex coilovers. This horrible creaking recently began ~ 1500 miles after installation. Sound is definately from left front and appears to be from the coilover itself. Only other changes to front suspension are Perrin PSRS, Whiteline steering bushings and STi Brembos.

This has been driving me nuts. Many other posts w/ similar problem. Lot of threads point to strut top nut as problem, but it's tight. I sent this video to Tein (after they suggested checking strut nut) and they have no answer either, yet.

Many threads suggest "blown strut" and I asked Tein to confirm from video if these symptoms are consistant. I've already taken practically everything apart once (including pullling off brakes and checking them). I don't want to go to hassle/$$$ of changing out strut just to rule-out that as a remote possibility.

Car has just under 10,000 miles. One track day and a dozen+ snow days, but problem began before track (very mild at that point- I attributed it to PSRS bearing needing grease since there was a squeaking present shortly after PSRS installed and weather was quite cold). That sound was very mild and just squeaking. Current problem has gotten progressively worse since coilovers installed. I think that this problem is different than the earlier squeaking initially heard in COLD weather after PSRS installed. Temp now in 80's and noise is much louder which is why I think it's a different problem altogether.

Strut top nut is tight @ 43 ft. lb. All other suspension parts, including sway bushings, were rechecked for tightness and regreased where appropriate.
I reinstalled/regreased the PSRS mount on that side (what a PITA) w/ NO change in sound. Noise is not associated w/ steering nor felt through steering wheel.
Also liberally sprayed LPS2 on the strut= no change.
Also double-checked all spring perch heights= to spec.
Also, axle nuts are tight and there is no play in wheel (i.e., not the bearings)

There is ALSO a very loud, solid "clunk"/"thunk" when brakes applied, though this seems to be coming more from the forward center, under floorboard area. There is definately SOMETHING "shifting or sliding" just after brakes applied and as the COG shifts forward. This second problem, which started at same time, may/may not be related to the suspension creaking/squeaking.

Any further ideas or suggestions? (beleive me, finding nearest cliff has crossed my mind...)
norm

 

yesterday I had a (brave) friend lay down next to front wheel while I drove the car over a 2x4 (to compress/stress suspension components). He said that the sound does not appear to be coming from the strut area, but from "lower down" in the subframe area.

As I said, soon after I had the Perrin PSRS installed a mild version of the current problem began as just a creaking w/ suspension loading, worse in cold weather, that I attributed to PSRS bushings (and indeed, on removal and inspection last week they were lacking any grease and showed signs of friction wear). The problem became worse and of a different quality after the Teins were installed which is why I beleived this was a new problem. After greasing the PSRS bushings there was no change whatsoever in the current problems.

ALSO, after rolling a couple feet and then stomping on the brakes there is a loud "shift" CLUNK of some component that is definately moving or sliding and then "catching" (with a solid clunking). There is obviously play somewhere in there.

Even though I've already checked this, I think today I will recheck front end links and subframe. Perhaps I will even remove and reinstall both (PITA). I know that stiff coilovers and lowering puts a lot of stress on endlinks. On inspection, however, bolts were to spec and they appeared undamaged. Perhaps aftermarket end links would be a good idea, though seems $$ overkill w/ factory front swaybar. I could dump another couple hundred $$ for front SB and endlinks, but I was quite happy with suspension set-up before this problem began. VERY neutral and controllable on the track. I really don't want/need more swaybar up front.

Anything else down there to check that anyone can think of (that I haven't already mentioned)?

thanks,
norm

 

hmmmm.... The bushings are a good guess. I don't know if greasing them will make a difference.


Also, you might have a bent strut. You said they were brand new right? Doesn't mean they came to you in perfect condition. Also veryify that your are running GD and not GC. There might be clearance issues.