Big Sky Euro

Okay guys, give me your feedback. It's at the point where I'm starting to get even more anal about it than normal.

I have this 'clunk' I've been looking into it for a while now.

It was originally at a start or coming to a stop (real slow). Brakes didn't solve the issue. I'm still investigating and the number one suspect became motor mounts. Then that got bumped for subframe welds/crease issues (as identified via AW earlier this week).

Rememeber when I got really annoyed with my dragging front bumper and I pulled the front off? Maybe not. Well, I found, what I believe is a broken rebar mount. I can't put one side all the way on (bolt won't catch) and can't pull the other off (bolt appears to be bent).

My deductions so far:

1) FMIC pipe on D side is sitting funny against something causing that abrasive high/squeal noise. This is no doubt attributed to the fabbed support system I rigged due to the non-functioning rebar mount on that side.

2) My oil temp sensor is leaking oil

3) Does anyone have anything to stop my nappy chiping of brakes as I drive down the highway? That drives me bonkers.

and finally, my Moriarty:

4)That 'clunk' thought to be originally brakes, the mount, now subframe: is as yet undetermined. HOWEVER, I decided to get a bit rough with the lady tonight and while it was running (don't know if this has anything to do with it) really started moving that D side front end around.

Bouncing, back and forth, yaw, pitch, lateral down the right side, all of it. Even just bouncing makes that sound. But I have to really work that car. It's not a 'clunk' per se. It can be a prolonged groan but not that abrasive metallic sound. But it occurs when I move the car up and down?

The shock's not leaking and it stops instananeously when bounced.

Control arm?

Subframe? (I know this is rare, but's happened to two cars on AW)


So I AM planning on doing a couple things right away.
1) Buy new front rebar mounts and bolts- Any of you have sources?
2) Check that sensor leak

optional:
1) While everything's apart, put that USP front on finally since I have almost NO room for the FMIC
2) Sell motor mount and focus on possible CA / Subframe issue

will not be considered:
1) Selling the car
2) Selling myself for car parts

About the "clunk"...I would keep it simple and start with the thought of a control arm or sway bar bushing...maybe even a strut bearing or bushing or a subframe bushing. Those are notorious for going bad/soft on VAG cars. Unless you took a really hard hit on that subframe I would really be hard pressed to say it's a bad weld or a crease in the steel. Also I would *think* that if the subframe were damaged that it would walk or wander a little bit and your alignment would be off?

I would also take a hard look at your dogbone aka Engine Torque Damper - that could be the culprit if the arm or bolt is broken or if the bushing is toast.

I don't know what your rebar looks like or how it attaches (aftermarket FMIC?)...I would just get new mounts and bolt them up. What brand of FMIC are you running?

Have you noticed the noise more as it has been getting colder?
Your brakes chirp on the highway?

For parts check out:
http://www.mjmautohaus.com - great site for parts/good prices.
http://ecstuning.com - I order a lot of stuff from them too
http://germanautoparts.com - rocks A+

Fix that leaky temp sensor with some teflon tape on the threads...

Edit: Or you should just get a new one because teflon on the threads can cause problems, unless you are really crafty and careful with it. Plus it shouldn't need it because it has a seal already. You could also use a high temp thread sealer...

Thanks Mike. You know, maybe we should hook up and try it isolate this sound. I'll bring some beers. I have two very good friends who both own shops in Denver and although I get most of parts via the above links, I'm ordering some of these through them.

I'm going to do a lot of those little maint. things in the next month or two (probably Jan. since I'm using money to ride over the holidays).

I've got a leaky VCG as well. I'm ordering new support mounts for the rebar as well.

I have to get my TB done in 5-10K but I'm not ordering that yet.

My FMIC is a Eurocode.

My D-side brake does squeak on the highway specifically when I turn right. I think I warped the rotor.

JayRyan wrote:Thanks Mike. You know, maybe we should hook up and try it isolate this sound. I'll bring some beers. I have two very good friends who both own shops in Denver and although I get most of parts via the above links, I'm ordering some of these through them.

I'm going to do a lot of those little maint. things in the next month or two (probably Jan. since I'm using money to ride over the holidays).

I've got a leaky VCG as well. I'm ordering new support mounts for the rebar as well.

I have to get my TB done in 5-10K but I'm not ordering that yet.

My FMIC is a Eurocode.

My D-side brake does squeak on the highway specifically when I turn right. I think I warped the rotor.

Count me in - my garage is full right now, so unless you know someone who wants a B3 shell, I hope you have a warm place to work?

Checkmark on all the rest of your issues...but the brakes: does your pedal pulse up and down when you brake? Thats a good indicator of warpage. A squeak is usually a pad/rotor issue from my experience.

And, if you have a jangle when going slow you have a rock between your hub and speed sensor Ask me (or Aeron) how I know...

I will bring my tools - name a time and a place!

Cool. Right now, it's simply diagnozing the current "clunk." So yeah, get the car up, shake things around, drive it, etc. I think I'm free this weekend.