Mid H&R Spring Install... Need Input on Clunk

[07misanored]

Hey guys,

I am installing the H&R sport springs on my car. Started on them last evening and it went very well. Did the front right corner, got everything out and back installed with the new spring without removing the DRC. Really wasn't bad at all. I was very satisfied with the project at this point as I had about 3.5 hours into the first corner and Im figuring the other front will take 2-3 now that I'm familiar with the steps.

After getting the car all back together I dropped the car back down and unsprisingly the ride height was only about 3-6 mm lower than the oem side. I realize these springs are brand new and will settle some in the first couple hundred miles so this doesnt concern me much. My concern is I have a clunk when I took it for a test drive! Any bump/rough pavement caused a clunk. Driving on smooth pavement I swerved back and forth and no clunk...but bumps are making a bad noise.

My number 1 suspect is the top strut nut, I had no idea how tight/far to install this. I blieve I have about 5mm of thread sticking through the nut on top currently. Does anyone know a torque spec or anything on how far this should be on? I am thinking taking the strut out again and tightening this down farther might help?

Only other thing I can think of is orientation of the perches? I can tell you for a fact that the springs are sitting in their propper spots in the rubber isolators, but I am not certain if the isolators are supposed to be clocked in a certain direction?? I did notice my spring is installed 180 degrees opposite from HEo2TEC in the FAQ install. Is this improtant?

Any ideas or help is appreciated guys. Im sure I will love the springs (especially once the actually settle and lower the car) and I have proved to myself the install is do-able, I just have to figure out why im getting this knock/clunk.

[ArthurPE]

verify that the srpings are oriented on the perch properly

mine lowered the front 10-12 mm
yours will probably settle after some time, but not much, mine are pretty much the ame after 9k miles or so
that is what I like about them, mild drop, almost oem quality ride

compare the H&R side to the oem side
perch
threads on strut top nut

[07misanored]

I am begining to wonder if my car was fitted with SS+ springs originally...as I am currently not seeing near that drop. Last night was sitting at 26.25" to the fender lip with completely worn tire that is getting ready to be replaced...so that is 26.5 with new tires. Like I said I know the springs are in the rubber isolators correctly...but do the isolators need to be rotated to a specific position on the metal parts that support them? If I remember correctly the underside was just flat so I didnt think they needed to be timed...but maybe they do?

I am begining to to think I should begin on the other side, but as I proceed make precise note of all postions of perches, isolators, bumps stops, springs etc. by marking everything with a paint marker and even taking pictures... then reassemble with the H&R spring to the exact same postions and see if I get a clunk on that side as well. If no clunk I just wil go back and re-do the first side putting everything to the same orientation.

side question...What keeps the strut rod from poking through the upper mount? I know the nut keeps it from pulling out, but when the suspension compresses what keeps the rod rod from extending up into your hood and forces the rod to go down into the damper? Thinking about how it went together I dont remember anything...

Im frying my brain trying to figure this all out....all for it to look a little better with the new wheels

[ArthurPE]

I am begining to wonder if my car was fitted with SS+ springs originally...as I am currently not seeing near that drop. Last night was sitting at 26.25" to the fender lip with completely worn tire that is getting ready to be replaced...so that is 26.5 with new tires. Like I said I know the springs are in the rubber isolators correctly...but do the isolators need to be rotated to a specific position on the metal parts that support them? If I remember correctly the underside was just flat so I didnt think they needed to be timed...but maybe they do?

I am begining to to think I should begin on the other side, but as I proceed make precise note of all postions of perches, isolators, bumps stops, springs etc. by marking everything with a paint marker and even taking pictures... then reassemble with the H&R spring to the exact same postions and see if I get a clunk on that side as well. If no clunk I just wil go back and re-do the first side putting everything to the same orientation.

side question...What keeps the strut rod from poking through the upper mount? I know the nut keeps it from pulling out, but when the suspension compresses what keeps the rod rod from extending up into your hood and forces the rod to go down into the damper? Thinking about how it went together I dont remember anything...

Im frying my brain trying to figure this all out....all for it to look a little better with the new wheels

perhaps someone can post the parts diagram
iirc large washers bear the up force

my oem (non SS+ was 26.6" in front, 26 or so in the rear, with H&R ~26.1 and 25.6)
you need to check the sticker in the book to see if you have SS+, do a search here and the code will come up
this may help http://www.jimellisaudiparts.com/showAs ... odelYear=0
search around, all parts for the RS4 can be found, good reference

[07misanored]

Figured the clunk out. Almost too embarresed to post this but it might help someone else searching for answers someday so why not.

I just found a small inconspicous looking washer on the ground in my garage near where I was working last night. Upon further investigation and in part thanks to ArthurPE's link to the website that has parts diagrams, have determined that this washer is essential for operation.

This washer being 12.1 mm I.D., 20 mm O.D. and 4 mm thick lets the M12 threads on the end of the strut rod pass through it but not the slighly larger O.D. of the non threaded portion of the strut rod. This must have fallen out of the upper strut mount when I was working without me noticing. Without this small washer in place the strut rod can travel right through the upper mount upon suspension compression over bumps, causing it to hit the sheet metal in the top of the strut housing...creating the clunk noise.

All sorted out now and onto the rear springs.

On a side note I did check my option codes and have a 2MC code which is I believe the regular sports suspension not the SS+ (super sports). I did however notice that the coil spring I removed from the front had 1 green and 3 white markings on it which I am trying to figure out if that was the factory spring or someone had it replaced with a different Audi spring at some point???? I see HEo2TEC's spring had one pink and 2 yellows, anyone else know what true factory RS4 springs should have color wise?

Thanks for the input guys.... I promise lots of pictures here in a week or so. Doing the springs in preparation for a new stance including Avant Garde's new M550 concave 5 spoke wheels. The car is being photographed for promotion of these wheels in Avant Garde's media as they just came out a couple weeks ago.

[07misanored]

Appologies for bumping my own thread but just thought I would chime in and say the install is complete. Did the other side of the front and both rears in about 5 hours last night. Pretty thrilled with the results...sitting at 25.75 front and 26.0 rear .....this is with current tires on the wear bars though so it will rise .25" here in 2 days when the new pilot super sports go on. Photoshoot is sunday witht the new wheels and rubber. Time to start cleaning tonight. Will start a new thread and post pics. Heres 1 crap iPhone pic of the result of the H&R springs to make this thread slightly less boring.

[Teutonic Tuner]

Looks superb that 07, perfectly matched gaps front and rear. Just checked the pics I took of my spring colour codes and I have 2 green stripes & one pink on my fronts, mine is standard suspension. On my E46 M3 the spring colour codes related to the options you had fitted to accommodate any extra weight etc apparently, verts had different colour codes as well.

Nice job by the way and glad you got it sorted in the end.

[ArthurPE]

Appologies for bumping my own thread but just thought I would chime in and say the install is complete. Did the other side of the front and both rears in about 5 hours last night. Pretty thrilled with the results...sitting at 25.75 front and 26.0 rear .....this is with current tires on the wear bars though so it will rise .25" here in 2 days when the new pilot super sports go on. Photoshoot is sunday witht the new wheels and rubber. Time to start cleaning tonight. Will start a new thread and post pics. Heres 1 crap iPhone pic of the result of the H&R springs to make this thread slightly less boring.

looks great, red suits the RS4 really well

how much fuel in the tank when the pic was taken?