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BMW 3-Series and 4-Series Forum (F30 / F32) | F30POST > Technical Forums > Suspension | Chassis | Brakes > Left side "clunk" noise during heavy cornering + low speed bump (RESOLVED)
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      10-13-2018, 04:54 PM   #1
teapain
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Left side "clunk" noise during heavy cornering + low speed bump (RESOLVED)

I need help diagnosing a "clunk"/loose metal noise on the left/driver side.

It's present during these situations:

1. Whenever I hit a moderate bump on my front left wheel during hard cornering to the right -- and only right. Like when I'm going on an on-ramp.

2. At moderate speed when I go over large bumps in the road like one of the larger protruding lane reflectors on the road.

My car is at 70k and have just replaced both lower thrust/control arms (with M3 arms), sway bar links, struts + shocks (Bilstein B6 on Dinan springs) and tie rods. The noise was present BEFORE all the replacements and is still present after.

Could it be a sway bar bushing? Steering? It's not something that arises frequently but it does rear its head during more spirited driving ... which really take away from the experience.

Thanks

-------
UPDATE 1:

So I finally received the service kit. See picture below.

However, I decided to hold off on installing the kit and just try tightening the problem three-prong steering cap/bolt.

1/8 clockwise turn fixed the problem. Initially tried 1/4 which made the steering stiff and prevented it from going neutral after a turn. So I backed it out to 1/8 and it was perfect. No more knocking noise on bumps and no more knocking noises when steering wheel is shuffled left and right when car is off.

[IMG]https://i.ibb.co/nqG2kHH/Screen-Shot...2-36-30-PM.png[/IMG]
[IMG]https://i.ibb.co/bXRfHZY/Screen-Shot...2-36-35-PM.png[/IMG]
[IMG]https://i.ibb.co/zJ22Thw/Screen-Shot...2-36-41-PM.png[/IMG]

UPDATE 2:
Noise came back after 10-15k. I went ahead and installed the service kit. So far after 10k, still no noise. Also, Harbor Freight sells an adjustable pin wrench that works great for the three-prong cap -- no need to buy an special BMW tool. https://www.harborfreight.com/adjust...nch-36554.html
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Last edited by teapain; 08-03-2020 at 02:19 PM..
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      10-13-2018, 10:28 PM   #2
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This is just omnipresent with our steering racks, very common. I have it too.
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      10-14-2018, 11:28 PM   #3
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Quote:
Originally Posted by Eschmacher View Post
This is just omnipresent with our steering racks, very common. I have it too.
Really? 😞
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      10-15-2018, 12:04 AM   #4
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I've got this too. I started to notice within the last couple of months. 35k miles.
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      10-24-2018, 06:29 AM   #5
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BMW actually acknowledge there are "acoustic abnormalities" with the steering rack and having undergone around 14 part number changes they now sell a repair kit for ~£20

Scroll to the bottom of this link...

https://www.etkbmw.com/bmw/EN/search...0d/ECE/32_2071

The real cheek is that they arent doing a technical recall when they practically acknowledge there is a defect!!
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      10-24-2018, 12:07 PM   #6
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Quote:
Originally Posted by Davef30hull View Post
BMW actually acknowledge there are "acoustic abnormalities" with the steering rack and having undergone around 14 part number changes they now sell a repair kit for ~£20

Scroll to the bottom of this link...

https://www.etkbmw.com/bmw/EN/search...0d/ECE/32_2071

The real cheek is that they arent doing a technical recall when they practically acknowledge there is a defect!!
WHOA. Where does this piece go?? I'd love to give this a shot and see if it fixes it.

Edit: I'm dumb, it's a whole kit. Probably has a bunch of pieces. Maybe I'll order and see if I can figure it out?

Last edited by Eschmacher; 10-24-2018 at 12:13 PM..
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      10-24-2018, 12:17 PM   #7
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Related video about the repair kit:


From a comment on the video:
"I had this done two days ago by a BMW specialist garage. There is a few special tools you need to complete the work, not sure if a computer adjustment is needed.
The kit was released by BMW on the 18/09/18. It was fitted to my car 430d 18/10/18 and so far has transformed the drive, honestly it feels like a brand-new new car.
Get it done but don't do it yourself."

Sounds like I might consider doing this... I wonder how much my local shop would want
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      10-25-2018, 01:06 PM   #8
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Quote:
Originally Posted by Eschmacher View Post
Related video about the repair kit:


From a comment on the video:
"I had this done two days ago by a BMW specialist garage. There is a few special tools you need to complete the work, not sure if a computer adjustment is needed.
The kit was released by BMW on the 18/09/18. It was fitted to my car 430d 18/10/18 and so far has transformed the drive, honestly it feels like a brand-new new car.
Get it done but don't do it yourself."

Sounds like I might consider doing this... I wonder how much my local shop would want
This is very hopeful! Just called dealer about part because I can't seem to get it in the US online anywhere. Was told not available yet but dealers might get ETA in a few days.
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      10-25-2018, 02:30 PM   #9
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Does anyone know if the clunk is actually damaging anything besides whatever replacement parts are included in the repair kit? Is the clunk shortening the steering rack's life?
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      10-25-2018, 07:50 PM   #10
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Quote:
Originally Posted by Davef30hull View Post
BMW actually acknowledge there are "acoustic abnormalities" with the steering rack and having undergone around 14 part number changes they now sell a repair kit for ~£20

Scroll to the bottom of this link...

https://www.etkbmw.com/bmw/EN/search...0d/ECE/32_2071

The real cheek is that they arent doing a technical recall when they practically acknowledge there is a defect!!
Whats the part number? the link doesnt work.
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      10-26-2018, 04:50 AM   #11
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Quote:
Originally Posted by redbullfan View Post
Quote:
Originally Posted by Davef30hull View Post
BMW actually acknowledge there are "acoustic abnormalities" with the steering rack and having undergone around 14 part number changes they now sell a repair kit for ~£20

Scroll to the bottom of this link...

https://www.etkbmw.com/bmw/EN/search/selectCar/F30/Lim/BMW+320d/ECE/32_2071

The real cheek is that they arent doing a technical recall when they practically acknowledge there is a defect!!
Whats the part number? the link doesnt work.
Part number is 32 10 6 891 974
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      11-06-2018, 08:34 PM   #12
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Anyone else have any feedback on this repair? Install cost?

Here are the install instructions that I found.

https://www.newtis.info/tisv2/a/en/f...nit/1Vnc3X9PQZ
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      11-07-2018, 01:32 AM   #13
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Anyone else have any feedback on this repair? dealer install cost?
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      11-07-2018, 01:47 PM   #14
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I want to kiss the dude that posted the video!!

I've been dealing with a thunking noise from the left front of my car (for over 18 mths) that the dealer diagnosed as a failed EDC damper. The verdict a nearly $3K repair to swap both front EDC dampers......despite having a Platinum Extended warranty - dampers are deemed as consumables and not covered under warranty. I always questioned the diagnosis as there was no change in handling, no fluid leaking from the damper, and the suspension mode switching works just fine

I did the shake test with the car off like shown in the video and I have the exact noise in a very pronounced fashion. I'm certain this what the problem is.
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      11-09-2018, 04:19 PM   #15
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This thread is awesome. Thanks everyone!
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      11-09-2018, 08:11 PM   #16
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Quote:
Originally Posted by Davef30hull View Post
BMW actually acknowledge there are "acoustic abnormalities" with the steering rack and having undergone around 14 part number changes they now sell a repair kit for ~£20

Scroll to the bottom of this link...

https://www.etkbmw.com/bmw/EN/search...0d/ECE/32_2071

The real cheek is that they arent doing a technical recall when they practically acknowledge there is a defect!!
Looks like there are 2 suppliers for the steering racks.
TKP (thyssenkrupp) and ZF.

BMW are only describing it as an acoustic abnormality. So maybe they don't see it being a safety concern for a recall.
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      11-13-2018, 04:11 PM   #17
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Just make your own tool to tighten the 3 prong nut down or buy the $50 part and turn it a quarter of the way. I tightening mine up and problem went away. They get slop over time or were not tightened down enough from factory. I went through 3 steering racks and problem always came back. Decided to tighten down the cap 1/4 and problem has not returned in 2 years.
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      11-13-2018, 04:28 PM   #18
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Quote:
Originally Posted by D041987 View Post
Just make your own tool to tighten the 3 prong nut down or buy the $50 part and turn it a quarter of the way. I tightening mine up and problem went away. They get slop over time or were not tightened down enough from factory. I went through 3 steering racks and problem always came back. Decided to tighten down the cap 1/4 and problem has not returned in 2 years.

Did you make your own tool? If so what did you use? I have searched and searched for the tool from a US supplier. I can only find it in Ukraine for $25 + $75 shipping.
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      11-13-2018, 10:21 PM   #19
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Quote:
Originally Posted by D041987 View Post
Just make your own tool to tighten the 3 prong nut down or buy the $50 part and turn it a quarter of the way. I tightening mine up and problem went away. They get slop over time or were not tightened down enough from factory. I went through 3 steering racks and problem always came back. Decided to tighten down the cap 1/4 and problem has not returned in 2 years.
Very interested in details. Any pics of exactly what you tightened or what tool you made to tighten it?
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      11-30-2018, 10:25 PM   #20
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Sub'd. Just noticed the same thing starting about a week ago.
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      12-04-2018, 04:42 PM   #21
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FIXED!

So I finally received the service kit. See picture below. But I also decided to DIY the three prongs tool out of a piece of aluminum, some screws and bolts.

1/8 clockwise was what I needed for my car. Initially I tried 1/4 which made the steering stiff and prevented it from going neutral after a turn while driving. So I backed it out to 1/8 and it was perfect. No more knocking noise on bumps and no more knocking noise when steering wheel is shuffled left and right when car is off.



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      12-06-2018, 10:03 AM   #22
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Quote:
Originally Posted by teapain View Post
FIXED!

So I finally received the service kit. See picture below. But I also decided to DIY the three prongs tool out of a piece of aluminum, some screws and bolts.

1/8 clockwise was what I needed for my car. Initially I tried 1/4 which made the steering stiff and prevented it from going neutral after a turn while driving. So I backed it out to 1/8 and it was perfect. No more knocking noise on bumps and no more knocking noise when steering wheel is shuffled left and right when car is off.
Just to clarify, did you install the service kit, or just tighten the original?
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