[BluesDriver]

This is on a 328i coupe w/ about 31k miles.

So after the warranty expires I am getting this clunking/rattling noise from the front end that almost sounds as if something is loose. The sound is only noticeable at speeds under 20 mph on uneven roads. Also it only starts to make noise after I've driven a few miles and the car has warmed up.

I've already checked the strut tower bolts ( 2 of 3 since I can't get the one below the brace) and the sway bar end links.

Any ideas?

[HP Autosport]

Strut mounts and thrust arm bushings?

If it's changing with temperature, it maybe something internal with the valving of the struts.

[Akira88]

I've had the same problem for awhile on my 2008 E92 (manual). The dealer service guy couldn't define what it was and thought it might be coming from a normal play of parts in the braking system. I took it to an independent shop recently and the mechanic was sure it was the worn bushings. He changed them, but the sound is still there.

[hoopvillian]

Originally Posted by Akira88

I've had the same problem for awhile on my 2008 E92 (manual). The dealer service guy couldn't define what it was and thought it might be coming from a normal play of parts in the braking system. I took it to an independent shop recently and the mechanic was sure it was the worn bushings. He changed them, but the sound is still there.

Tighten up your sway bar end-links.

[feuer]

I don't understand why people are starting new threads for such common issues. This has been discussed many times before. It starting to aggravate me.

[Sidewinderpb]

Originally Posted by feuer

I don't understand why people are starting new threads for such common issues. This has been discussed many times before. It starting to aggravate me.

The nature of public forums

[HP Autosport]

Originally Posted by Sidewinderpb

The nature of public forums

[BluesDriver]

Originally Posted by feuer

I don't understand why people are starting new threads for such common issues. This has been discussed many times before. It starting to aggravate me.

Sorry for the aggravation.

I always try searching first but I only saw a couple of posts about this and none exactly matched my symptoms. Maybe I used the wrongs search words.

[BluesDriver]

So I ended up changing the sway bar end links and the rattle/loose bolt sound has gone away but the clunk is still there. When I removed the links, I noticed that the rubber seal was pulling away from the shaft/bolt and a good amount of grease had come out.

I also checked the sway bar bracket nuts. A couple were under torqued but tightening them did not solve the clunking issue.

Fyi, I went with Lemforder instead of OEM. Both FCP Euro and Bav Auto said there was no reason to spend more for OEM. On the Lemforder the bolt shafts are steal, not aluminum, but they do come with the nuts. One last point, you do not need a thin wrench as stated in the Bently manual.

[Three_thirty_I]

It happens, even when one searches, you don't always find the threads dealing with the issues you are looking for, so invariably create a new thread hoping that someone who has already "been down that road" can assist.

Now my part of this:

Last weekend I noticed my right rear shock bump stop was looking rather, well, it's falling apart, so will have to replace it, and being me, this means both the left and right will be replaced. Now, I don't go off-roading with this car LOL, so am still a bit surprised that this has failed. All I can think is that it is mostly age related since the car is a 2005 model albeit with very low mileage still. Then again, people that I have been in contact with say that these foam bump stops tend to either not last or are not the most durable should the car come close to bottoming out. I am going to get my shocks checked in any case, as well as all rubbers etc. This is my second motivation for doing this:

For as long as I can remember, this car, since I've owned it (bought in 2010 with 46k km on the clock), has always had a bit of a rattle on the front suspension when going over a slightly rough speed bump or going onto or off a bumpy driveway. Now, I am always gentle when going over bumps and try to avoid anything that might hurt the suspension, so either it's just one of those things, or something is a bit worn. It certainly hasn't gotten any worse over the years though. And also, the car has always run on RFT's which I don't think helps much either.

So I will have to see what I can find.

[Petrolhead3010]

I've been having the same issue as OP on my 08 335i coupe. Sounds like something is loose. I haven't checked anything, but if it's the bushings, is there a company that offers a polyurethane or hardened rubber upgrade?

[CPWINCH]

I have the same problem with my KW coilovers. It seems to be from the shock. I think it needs to be rebuilt

[alpineweissm]

I'm having a similar issue. It's difficult to pinpoint through search results. Can the knocks/clunks you guys have described be heard from inside the car with the windows up? The reason I ask is because I can hear a knocking sound over rough/uneven roads that sounds like it's coming from deep within the center of the dash. It sounds like something is loose.

[Petrolhead3010]

Originally Posted by alpineweissm

I'm having a similar issue. It's difficult to pinpoint through search results. Can the knocks/clunks you guys have described be heard from inside the car with the windows up? The reason I ask is because I can hear a knocking sound over rough/uneven roads that sounds like it's coming from deep within the center of the dash. It sounds like something is loose.

Yep. My noises are exactly like that

[Murf]

I've had the same noise for 50k miles (currently at 79k). I have replaced both front struts and mounts, front control arms, end links and sway bar bushings. None of this affected the sound in any way and I gave up trying to find the source.

I suspect it is either the brake calipers clunking or maybe something in the steering rack but since nothing bad has ever materialized over tens of thousands of miles I have learned to live with it.

[pinoye90]

It's not just one thing that needs to be checked.. I have the same problem currently which I'm trying to pinpoint. I will keep everyone posted once I have the chance to investigate.
1. Sway bar brackets from worn bushing
2. End links which I have already replaced with meyle brand. I will check the nuts if lose
3. Upper shock mount which are new but the washers needs to be placed correctly between the perch and the upper hat.
4. Less likely a shock problem which also are new b8

[Akira88]

An unexpected change in my case has been that the inspection done by the dealer puts the clunking noise as coming from the rear and not the front. They reported that it's the drive shaft and that the noise is more noticeable "during load reversal."

[gunnerxq]

What if it's bad engine mounts or a loose upper sway bar (that thing in the engine bay going from strut towers to the middle, under the cabin filter)

[BluesDriver]

Originally Posted by Akira88

An unexpected change in my case has been that the inspection done by the dealer puts the clunking noise as coming from the rear and not the front. They reported that it's the drive shaft and that the noise is more noticeable "during load reversal."

So was your noise happening only when the car has warmed up and whatever that is causing the noise has absorbed heat?

For me there is no noise in the "cold" morning but it shows up going home after sitting in stop and go traffic.

[Stream]

I also have knock-knock noise, coming from the front. It apears after warming up and only in warm (for winter) weather. There are no clunks when it's cold.
Struts are koni sport with 25.000km on it and all arms and ball joint were replaced within last 10000-25000 km.

[Akira88]

I took the car to an independent shop and they fixed the problem, no more clunking noises at last. The noise was actually coming from the front flange of the rear differential, but it was being transmitted through the driveshaft and that's why I was mistaken about the location. They adjusted and cleaned the flange parts, refilled it with Locktite and it's fine now. I also replaced the driveshaft for a rebuilt one. The service recommendation from BMW though is to replace the differential in this case, but my warranty expired before the BMW dealer was able to figure out the problem.

[Gohan335i7]

Hmm...