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Author Topic: Knocking from front end  (Read 1219 times)

Offline Mayney

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Knocking from front end
« on: March 06, 2020, 07:44:54 am »
Hi guys,

So a few months ago i purchased a stage 2+ manual edition 30.

The car has a whole rift of modifications, and with my recently increased mileage for work, it is starting to take its toll.

These mods include
Revo intake pipe with aem filter
Psi tuning turbo heat shield
RPC motorsport intake manifold VIS motorsport hpfp internals with the 5mm valve mod
Vibratechnic solid engine mounts & updated dogbone gearbox mount Welly intercooler 
rs4 valve
Relentless 3.5 downpipe
Miltek cat back (r32 style)

Suspension/brakes:
WAT racing coilovers (damper adjustment, solid top mounts/camber adjustment) Adjustable drops links
New inner tie rods and track rod ends
Anti lift kit
polybushed wishbone bushes & new bottom ball joints


Last week the the clutch failed (helix organic) - The rings on the outside of the pressure plate snapped.. the garage said the clutch itself looked pretty much unworn. Kind of weird but yeah, replacement helix organic fitted and all seems well.

A week later, the dogbone mount shat itself and the center bolt ripped from my gearbox. It looked to be running an uprated dogbone, after a bit of reading and a call to AKS i purchased a new genuine dogbone and the uprated small bush insert for it with the revised bolts.

The garage have then helicoiled my gearbox and fitted the new mount and a now i am getting a knocking from the front end again when under light throttle or letting off the throttle with the clutch engaged. More noticeable at lower speed.

Obviously the car is very stiff - I've yet to have a play with the damping adjustment but im hoping i can loosen it off a bit.

Originally when i bought the car i would only be doing <150 miles a week but now im having to do >600... As much as i dont want to sell i think i may have to once i have sorted this knocking.

Does anyone have any ideas on what this knocking could be? It doesn't sound like top mounts to me.
Owning this car has made me understand why people tend to mod their own cars rather than purchase modded ones, as although initial inspection led me to believe the car had been modded well, its starting to feel like the previous owners have cut corners and now i have to pay the price..




Offline pudding

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Re: Knocking from front end
« Reply #1 on: March 06, 2020, 04:17:20 pm »
I do a similar mileage to you and went through the same exactly the same parts as you, with the exception of different brands of coilovers and downpipe.

Because of that mileage, I went back to Stage 1 tune and standard engine mounts, but left the Vibratechnics dogbone and coilovers on.   Even the fast road spec Vibratechnics side mounts are too stiff for a daily, and they're rubber!  God knows how people live with poly mounts on a daily basis.

I absolutely love how it drives.  The coilovers are compliant (Ohlins) and the Vibratechnics dogbone keeps most of the engine movement in check, but it's just so much smoother and quieter compared to the full compliment of VT mounts.

My Helix has been OK for 50K miles luckily, but the pressure plate on that kit is made by Sachs, so not technically the fault of Helix.   Helix make their own (billet) pressure plates now, so take from that what you will! The Sachs sporting clutch kit is well known to be very heavy and unreliable, probably why Helix ditched their pressure plates.
One thing I have noticed running a far heavier clutch is the dual mass flywheel doesn't last long.  Something to bear in mind a couple of years down the line when it's starts rattling.

On/off the throttle at low loads/road speeds can indeed cause a jolt on these cars, but not a knock specific to that that I've noticed on mine.   A drivetrain knock is usually something loose or it's contacting something on the chassis.





2007 ED30 | 2009 TDI 140 | 2016 BMW 330D

Offline Mayney

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Re: Knocking from front end
« Reply #2 on: March 10, 2020, 01:01:50 pm »
Thanks for the reply!

Im not really looking at returning mine back to be more suitable as a daily driver, i may as well get another cheap run around for my commute. My car is insane when it works, 360+hp and 420lbft of torque. Id had a replacement flywheel in 2017 when the original helix clutch was fitted. When i had the new helix fitted they technicians said that the flywheel was well within tolerance too.
Im booked in with AKS next week for a service and a check over so im hoping i can get to the bottom of the knocks. I have a feeling its subframe related now... maybe lol. But yeah, the vibratechnics are very very stiff.



Offline pudding

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Re: Knocking from front end
« Reply #3 on: March 20, 2020, 06:37:07 pm »
It's well worth locking the subframe down with ECS Tuning/TyrolSport collars.  If the knocking is still there after that, it could be the infamous steering rack wear that we all have to tackle at some point.


2007 ED30 | 2009 TDI 140 | 2016 BMW 330D