Hey guys,
I recently installed the FRPP kit (new) on my 2009 from Tousley Ford.
When I go over bumps I hear a clunk in the front end. I believe it's the springs on the struts making the noise. While installing the FRPP kit I did notice that the top of piece that goes on top of the spring (which is attached to the strut mount) is different than my stock one. Also there is a small thing worn out rubber piece that goes over the top coil of my stock front spring which did not come with the FRPP kit.

Any ideas as to what might be wrong? I'm prett positive I installed everything right.

is your spring sitting in the strut right? is it shifting possibly? or tie rod

I made sure the spring is on the strut right. Unless it could have moved. Not sure on the tie rod but I never had the noise before the FRPP kit. I also replaced the end links thinking that was the problem but it wasn't

ya i don't even know why i typed tie rod... i mean to say end links.. cuz that's usually the issue. I didn't have an issue when i installed mine many moons ago on my old car. do you have an idea where the clunking is coming from? have someone stand outside the car when you go over a bump

Anyone?

Hey guys. I just remembered. The kit didn't come with any front isolators. Could this be the cause?
I re used the stock rear isolators but there's nothing in the front of the new kit to be reused nor with the FRPP kit

I would look for new rubber prices between the spring and the strut mount also go back and check your torque specs on all bolts. For recommends changing bolts and hardware every time you remove shocks and struts so that my be why your hearing a noise.

There are no rubber isolaters in the front.
The pre-assembled SVT struts have nothing but steel springs on steel mounts, and they don't make noise.

Often, it is the top strut mount bearing that makes the clunking noise.

Check the strut mount they are open ball bearings and some times the break and the bearing come out

Check the strut mount they are open ball bearings and some times the break and the bearing come out

There are no ball bearings in a stock Ford focus strut mount assembly.

The "bearing" is a plastic flange bushing that goes between the spring retainer plate and the strut mount.

The whole setup is brand new from Tousley including the strut mount. I did however notice that the top cap on the spring of the frpp kit is different than my stock one and I believe so is the strut mount.

Also, here is a pic of the top strut bolt. Does it look right to you guys?

http://img.photobucket.com/albums/v333/mustangguy/32F8667E-1A17-45D8-AB8B-5504D71CD7BD-2305-0000017E22B92A47.jpg

Look fine to me, I would just check the torque on them real quick

There are a few threads on this being a common problem on several years of Foci, with the Sway Bar End Links being the solution. IIRC the stock design wears out quickly, and switching to a nicer aftermarket one like Moog's (with a grease fitting) usually fixes it. I've got my Moog's from Rock Auto, just waiting to install in the next week or two. I think it is was under $50 for both

edit: Just re-read your reply, you have already replace your end links! I also saw the thread where you said you used the replacement Ford ones, I don't know if these are better or worse than the Moog's. The main noise I'm experiencing with my FRPP is almost like a squeaking/ somewhat metallic sound, and I think from the rear. Happens at low speeds and on relatively flat roads. I'm probably going to take off the wheels and re-torque everything.

My endlink problem is a distinctive pop/clunk sound, usually happens when I'm pulling into an inclined house driveway, and reversing out to park my car.

My endlink problem is a distinctive pop/clunk sound, usually happens when I'm pulling into an inclined house driveway, and reversing out to park my car.

My noise sounds similar. How sure are you it's you'r end links?

Also, I never had this noise with the stock suspension

Which frpp kit did you buy? What model number? What springs did you use?

Which frpp kit did you buy? What model number? What springs did you use?


I can't rember the part numbers off hand but I ordered them through Steve @ Tousley Ford. I know they are 2006-2007 FRPP shocks and struts aswell as springs. There was 2 options for the springs. The first ones were discontinued so he got me the second option which were just supposed to be slightly stiffer

I would try to isolate the side that is making noise. Find a pothole or other road obstruction and drive just one wheel over it.

How did you assemble the strut?

I would try to isolate the side that is making noise. Find a pothole or other road obstruction and drive just one wheel over it.

How did you assemble the strut?

Both are doing it but the right one is worse and louder.

I compressed the spring, put it on the strut, put on the top hat, bearing and strut mount. I got the strut nut on fairly right and released the spring compressor. I then tightened down the strut nut real tight and installed it on the car. I then was able to get the nut to tighten another 1/4 turn on each side once in the car.

Did you set the strut nut to the correct torque?

Did you set the strut nut to the correct torque?

I didn't use an actual torque wrench but its on Really tight. I'd be willing to bet its on tighter than it is lose

You may want to keep in mind that this isn't something the car was designed for, aftermarket parts have adverse affects on many things in the car. If your dealing with a noise just isolate the thing and see where it takes you, definitely don't ignore it though.

Hmmm...

Try removing your sway bar end links and see if the noise goes away. Let's try to remove variables.

The frpp absolutely should not clunk. I've put four of these damper sets on two different cars myself and never had a problem. Something ain't right. Besides, Ford designed this suspension to work with the car.

Also it's *possible* to over tighten a strut mount nut and cause the bearing to bind up, but it'd be hard to do without an impact wrench so I doubt that's the problem.

Hmmm...

Try removing your sway bar end links and see if the noise goes away. Let's try to remove variables.

The frpp absolutely should not clunk. I've put four of these damper sets on two different cars myself and never had a problem. Something ain't right. Besides, Ford designed this suspension to work with the car.

Also it's *possible* to over tighten a strut mount nut and cause the bearing to bind up, but it'd be hard to do without an impact wrench so I doubt that's the problem.

I was thinking that. If the front swaybar is making the noise and I undo the end links, would the noise more than likely not happen with the end links off?

Also, I know I did tighten the strut bolt very tight. Is say at for sure 90 ft lbs. I can try to check with my Torque wrench.