Front Sus Buckling Noise - PolyU Bushings - Help!

[2003 V8 TT]

Friends,

After 1,000 miles with PUK Polyurethane Suspension Bushings all around, my front is experiencing some problems. I'm not saying these syptoms are caused by the new bushings, but I haven't had these noises before installation. Please let me know what could be the root cause of these issues...perhaps they may be workmanship/assembly problems. Here it goes:

One day, I hit the brakes hard and heard a "clunk" in my front suspensions. But intermittently, it went away. I then hear the same banging/buckling sound when my wheels are at full steering travel while the suspension is being elevated or lowered. The problem is not present when the vehicle is in normal cruising mode. To summarize, I hear this knock/bang/buckling noise (sounds like the fiberglass body is being twisted in half!) under the bonnet when the vehicle:

1. Brakes hard or accelerates hard

2. Undergoes suspension movement while at full steering angles.

Once again, this problem was not present with my stock rubber bushings, but only after the PolyU install. If some of you recall an earlier thread on the PUK Bushings, my front control arms, along with those belonging to others who use PUK Bushings, had to be modified to fit correctly.

Given all this data, what could be wrong with my front suspension? Should I cease driving my car immediately to prevent further damage (painful given the short driving seasons in New England)? Damage of what? The steering tracks straight, does not vibrate, and is silent under all other driving conditions. I wonder what is binding.

Would appreciate any tips and advice you can offer. Thank you very much!

[L8Braker]

Did you use plenty of Litium grease when installing those bushings? Poly bushings are notorious for making noise if not properly lubed.

Edited June 15, 2006 by L8Braker

[TEAM MAG]

Check the body to frame mounting bolts in the front...especially the two you can access through the front bonnet. I found those two loose on my 2002 with only 1500 miles on her. I was hearing a loud clunk when I entered and exited driveways or sometimes on hard acceleration. Since tightening them, have had no issues for 5k miles.

[2003 V8 TT]

Check the body to frame mounting bolts in the front...especially the two you can access through the front bonnet. I found those two loose on my 2002 with only 1500 miles on her. I was hearing a loud clunk when I entered and exited driveways or sometimes on hard acceleration. Since tightening them, have had no issues for 5k miles.

<{POST_SNAPBACK}>

Thanks for the responses so far. Could you please (as best as you could) verbally guide me towards where these two structural bolts are in the front bonnet?

Also, were they visibly/hand-turnable loose or did you have to take a wrench up to it to feel that it was loose (not hand-turnable loose). And were there visible damages done during this clunking phase?

Thank you!

Edited June 15, 2006 by 2003 V8 TT

[TEAM MAG]

They are located inside the front bonnet, each directly in front of the driver and passenger. The driver side bolt is slightly under the master cylinder area and the passenger is easily visible on that side. You will have to get under the front to access the nut and have someone on top hold the bolt in place. When I checked the torque, they were not hand loose but were easily movable with a wrench. I found no damage at all. Hope this fixes your clunk.

[2003 V8 TT]

They are located inside the front bonnet, each directly in front of the driver and passenger. The driver side bolt is slightly under the master cylinder area and the passenger is easily visible on that side. You will have to get under the front to access the nut and have someone on top hold the bolt in place. When I checked the torque, they were not hand loose but were easily movable with a wrench. I found no damage at all. Hope this fixes your clunk.

<{POST_SNAPBACK}>

Thank you very much, I will take care of this ASAP. By the way, it WAS duing entering and exiting of the driveway that I noticed the clunk, which I tried to describe via suspension travel at hard angles (since I have a steep driveway, which requires this angle of attack to prevent scraping! Thanks again).

Best,

Will