impossible noises from the front of my Allroad

[red-ur]

Hello All.

I have a 2002 Audi Allroad 2.5 tdi with nearly 200,000 recorded mile. My first foray back to Audi since the heady days of a beloved restored 85 ur-quattro.

Since taking custody of my Allroad i have changed the timing gear and other associated belts, pulleys and tensioners. Also, the water pump and thermostat.

After sorting the motor jobs i moved to the not-too-satisfactory air suspension and promptly removed the air-ride components, compressor and control unit and replaced them with stock A6 Avant sport quattro coil-over-strut assemblies from a salvage car. I've set the height of the car to something in the region of level 2, by raising the A6 spring seats with custom turned spacer rings, that have worked a treat.

After getting the suspension sorted i started on the front linkage and control arms, all of which appeared to be worn and in need of attention, due to the associated clicks and bumps that accompanied the ride.

I've changed all the front upper front & rear position control arms; the lower front and rear position control arms. Not to mention the ARB mounting bushes and drop links, as well as the track control joints. The ride has improved dramatically and is much improved both in handling and sound; however.....there's still a momentary click / bump - particularly to the OSF, when i slow to a stop, or when i pull away from the parked position.

Have i missed something here? Everything is as tight as a drum on the suspension. There are literally no weak links as the numerous checks have attested.

I'm considering the possibility of a worn CV joint; there is some lateral / longitudinal play evident, though pretty minor.

I'm also considering wear and tear in the OSF Caliper, which is perhaps allowing the pads to float back and forth in the seats. However, the knock / bump/ click still occurs when i pull away after gearing down to a stop and finishing off with the handbrake, in my attempts 'not' use the front callipers.

Rolling back on a bank and braking also produces a click, as does moving forwards after the roll back test.

Has anyone got a suggestion because it's irritating the heck out of me after doing so much work to get the car how i want it.

Incidentally, on my 02 vehicle, i don't get any errors with the ESP or ABS after removing the air-ride gear unlike 03 cars and newer. also, I'm very happy with the Allroad look and the newly installed sport suspension. what's more, the air-ride gear went on ebay and covered the cost of the converstion and some :biglaugh:

Cheers for looking.

[Crasher]

It would help to hear the noise but it reminds me of a shifting pad. Also, did you fit all new bolts to the suspension and did you tighten the lower arm inner rubber bushes with the wheels loaded and did you set up the drop distance on the upper arms with the assembly off of the car?

[red-ur]

Thanks Crasher. I jacked up the hubs to their normal working positions before tightening the inner bolts, and set the upper control links to the optimum angles before refitting the struts. The lower arm inner bolts were re-used, but were correctly torqued (and some) and re-checked a week later after some 500miles. I'm with you on the shifting pad theory. However i do have a small doubt, because the knock does occur after not using the foot brake as well - as if the links and control arms had not just been replaced.

[Crasher]

Are all eight links of a reputable make, no Chinese rubbish?

[red-ur]

That's a fair question.

TRW 'as good as genuine' lower rear arms. The rest are all eurocarparts and ebays finest 100% non genuine.

I'm pretty sure i've a good idea concerning your thoughts on the later statement, and yes, there probably is a bit of a far-east influence in the overhaul somewhere in the mix. However, i have re-checked all the joints and all movement remains rigid and tight, with good strong resistance and absolutely no sidewards / in-out play.

[Crasher]

TRW make brilliant suspension arms, on a par with genuine, they may even be the OE supplier to VAG. The other "stuff" is probably where your problem lies or maybe rack/track rod inner/outers.

[red-ur]

Thanks Crasher.

Yup. The original items were TRW stamped Audi parts. So those new arms will probably outlive the vehicle. The non gen stuff could be a worry however. Thanks again.

[Eshrules]

Euro's aren't renowned for their quality suspension parts. I've lost count of the number of repeat bearing replacements I've made because of people insisting on fitting their crap.

[red-ur]

Update on the strange noise from the front of my Allroad. The noise is dying away and all but gone, particularly when i'm on my own in the vehicle. It's beginning to feel like there was something seized or an unchanged joint was dry and stiff, that has begun to free up and move freely. The car was a trade-in, and standing for a long time before i purchased it. So maybe this was a factor. Fingers crossed it'll keep improving. Cheers all.