[Sail Boat]

Hey all,

When I picked up my CPO M235i, I noticed that the front suspension made a soft clunking noise when going over uneven bumps or dips. After reading dozens of threads on almost every BMW forum, F20 forums and 2addicts in particular, it appears that this suspension clunk from the front end is common and labeled "normal" by BMW. Many owners have tried a variety of remedies to reduce the noise, such as replacing tophats and/or the steering rack. Unfortunately, in most of theses scenarios the clunk either isn't fully resolved or comes back. The only real solution seems to be replacing the entire strut assembly. In any case it doesn't seem to actually affect the car from a safety or reliability standpoint, I just don't want to hear it anymore.

In addition to the annoying clunking, I'm just not pleased with my DINAN springs - although I like the way the M235i looks lowered a bit, I actually think I preferred the way the car handled prior to this modification. I have also changed my opinion on the adjustable suspension: to me, it's all novelty. It's not right in comfort mode and it isn't right in sport. I just want a suspension that feels great all the time (I know, that's a lot to ask).

As a solution, I'm very close to pulling the trigger on coilovers. I've looked at a variety of brands, namely options from Bilstein and KW, but I don't like the idea of coilovers that compromise piston stroke for lowering. In this case, it seems my only options are BC's BR coils and Ohlins, both of which are height adjustable via the shock body. Of course, I'll code out the EDC.

I really like BC's offering from a cost standpoint considering they can be spec'd with Swift Springs (amazing), rear valve adjustment extenders, and come with camber plates. Ohlins, on the other hand, makes some of the best dampers on the market and they are still cheaper than the KW V3 Plug and Play kit. While I'm in there I'll also install powerflex LCA and FSB bushings.

What do you all think about this plan? I really hope coilovers fix the clunking issue. Never know though, I could end up making the problem worse.

[XutvJet]

My guess is the clunking is related to the Dinan springs not seated correctly in the perch or hat and/or a failing top hat bearing or incorrectly torqued strut/top hat nut.

You'll likely be quite disappointed with the coilovers as they will likely be noisy, especially if they use their own top hats.

[Sail Boat]

Originally Posted by XutvJet

My guess is the clunking is related to the Dinan springs not seated correctly in the perch or hat and/or a failing top hat bearing or incorrectly torqued strut/top hat nut.

You'll likely be quite disappointed with the coilovers as they will likely be noisy, especially if they use their own top hats.

No, this noise existed prior to installing the Dinan springs, as mentioned in my post. They are installed property, removed both front struts to check. Although I suppose you could review the Dinan spring DIY thread I posted and let me know if you see any glaring issues with my install, but like I said this noise existed from stock. As far as I know, this is an issue that happens with many newer BMWs with EDC and theres dozens of threads about it - appears to be luck of the draw.

I'm a bit worried about the BC camber plates making noise, but as I noticed on other BMW and Porsche forums, they seem to be nearly silent. I'll have to check and see if OE tophats can be used.

[x233]

You are looking in the wrong direction. All the things proposed in the OP, individually and especially in combination, are likely to increase the clunking/noise, your primary concern, and decrease comfort. Especially and definitely the camber plates.

[Sail Boat]

I'm confused... The coilovers I've used in the past haven't been noisy, if at all? Is this just a BC issue? A few members on the forum that have Ohlins, KW and other brands have had no noise problems at all.

[Nugget]

Originally Posted by Sail Boat

No, this noise existed prior to installing the Dinan springs, as mentioned in my post. They are installed property, removed both front struts to check. Although I suppose you could review the Dinan spring DIY thread I posted and let me know if you see any glaring issues with my install, but like I said this noise existed from stock. As far as I know, this is an issue that happens with many newer BMWs with EDC and theres dozens of threads about it - appears to be luck of the draw.

I'm a bit worried about the BC camber plates making noise, but as I noticed on other BMW and Porsche forums, they seem to be nearly silent. I'll have to check and see if OE tophats can be used.

I have BCs on two cars (e36s) and get no extra noise from their camber plates.
I have Ohlins with Vorshlags on my M140i and they are pretty noisy. Not clunks or anything, just a fair bit more road noise.

[Gman235]

I was just reading through an explanation on the suspension and came across this:

"When this plate, or the springs get worn, a loud "clunk" is usually heard at full lock (the steering wheel turned as far as it will go in one direction) as the spring frees itself from the proper place on the plate and then snaps back into place. "

Think this could be it?

http://www.team-integra.net/forum/bl...-i-basics.html

[capt_and]

I have Ohlins with Ground Control plates. Yes there is more noise than stock. If I didn't track the car and was primarily focused on comfort, I would just go with stock. And yes, they were installed correctly by arguably the best race shop in TX.

[Dylan86]

KW coilovers with the KW supplied top hats do NOT make noise, or at least I've never heard this feedback from any of the BMW members, within these forums.. The same can't be said for the rest, though, especially when crossing over different branded hats and coilovers. Never had or heard of noise complaints coming from KW's, and have run V2/3's on my VW/Audi's for years, without added noise or knocking sounds. But they're a bit more pricey than the rest. Also heard fantastic things about Ohlins R&T, again never heard of complaints on those for noise, either. Either way, usually when you go from OE to aftermarket, you get better handling/feel, with the clause of other "pronounced" noises or sounds due to the reduced travel and increased damping. Things like bushings, links, etc become the next weak point after that, but unless you're running a really sticky tire and driving hard all of the time, you shouldn't hear much additional noise, if any, by simply installing coilovers...

I'll be installing my KW's which have the top hats (Clubsport model), and can provide feedback in a couple of weeks once the roads have been swept, here. Cheers,

D

[Nugget]

Originally Posted by Dylan86

Also heard fantastic things about Ohlins R&T, again never heard of complaints on those for noise, either.

Ohlins R&T don't come with top hats.
If you reuse stock they should be quiet, I used Vorshlag camber plates and there is a noticable increase in road noise transmitted.

[Sail Boat]

Originally Posted by Gman235

I was just reading through an explanation on the suspension and came across this:

"When this plate, or the springs get worn, a loud "clunk" is usually heard at full lock (the steering wheel turned as far as it will go in one direction) as the spring frees itself from the proper place on the plate and then snaps back into place. "

Think this could be it?

http://www.team-integra.net/forum/bl...-i-basics.html

unfortunately it isn't steering related. it sounds a lot like the swaybar is walking, as if the bushings are failing. Interestingly, the noise is reduced with the dampers in sport +. I suspect this is due to the tighter dampening reducing travel a bit.

[Anthony235]

Originally Posted by XutvJet

You'll likely be quite disappointed with the coilovers as they will likely be noisy, especially if they use their own top hats.

All my experience with coilovers with other cars and this car (KW Clubsport) would disagree with this statement.

Originally Posted by Nugget

I have BCs on two cars (e36s) and get no extra noise from their camber plates.
I have Ohlins with Vorshlags on my M140i and they are pretty noisy. Not clunks or anything, just a fair bit more road noise.

Same here. I've probably had BC's on 4 cars and never had any extra noise.

Originally Posted by Nugget

Ohlins R&T don't come with top hats.
If you reuse stock they should be quiet, I used Vorshlag camber plates and there is a noticable increase in road noise transmitted.

My buddy has them on his M2. Uses OEM top hates. No noise.

[Sail Boat]

Just got off the phone with my favorite BMW specialist, RRT in VA. They are aware of the issue I am referring to, having experienced it with an M235i and multiple F8X cars. Their theory is that the OEM Top Mount design is the culprit. While I don't entirely understand why this is the case (something about minimal tophat rotation in comparison to previous BMW designs and the shock body), I suppose it can make sense when considering that I have not heard any noises from the rear... despite the entirely different suspension design.

In their experience, the installation of aftermarket suspension with camber plates seems to totally solve the problem. I think I may attempt purchasing camber plates first and see what result I get. After all, this would provide more camber adjustment up front and help me retain the EDC.

I also need to redo my brake rotors within the next 5k miles, so maybe I'll just do a close-to-50k miles spa day.

[Anthony235]

Originally Posted by Sail Boat

Just got off the phone with my favorite BMW specialist, RRT in VA. They are aware of the issue I am referring to, having experienced it with an M235i and multiple F8X cars. Their theory is that the OEM Top Mount design is the culprit. While I don't entirely understand why this is the case (something about minimal tophat rotation in comparison to previous BMW designs and the shock body), I suppose it can make sense when considering that I have not heard any noises from the rear... despite the entirely different suspension design.

In their experience, the installation of aftermarket suspension with camber plates seems to totally solve the problem. I think I may attempt purchasing camber plates first and see what result I get. After all, this would provide more camber adjustment up front and help me retain the EDC.

I also need to redo my brake rotors within the next 5k miles, so maybe I'll just do a close-to-50k miles spa day.

If you think the soft clunking you're getting now is annoying....wait until you get those camber plates installed on OEM suspension.

[Sail Boat]

Originally Posted by Anthony235

If you think the soft clunking you're getting now is annoying....wait until you get those camber plates installed on OEM suspension.

Yeah, I think you're right!

After researching the forum, specifically the K-MAC thread, this sounds like an awful idea hahaha. I've done quite a bit of research on the manufacturer of the EDC shocks, Monroe (called "intelligent suspension"), which spreads into VAG and other manufacturers... the consensus is that they aren't well liked.

Going with the BC BR's w/ Swift Springs, sounds like the best option!

[Anthony235]

Originally Posted by Sail Boat

Yeah, I think you're right!

After researching the forum, specifically the K-MAC thread, this sounds like an awful idea hahaha. I've done quite a bit of research on the manufacturer of the EDC shocks, Monroe (called "intelligent suspension"), which spreads into VAG and other manufacturers... the consensus is that they aren't well liked.

Going with the BC BR's w/ Swift Springs, sounds like the best option!

Great choice and my first choice, but they weren't available at the time.

[amw896]

Originally Posted by Sail Boat

I'm confused... The coilovers I've used in the past haven't been noisy, if at all? Is this just a BC issue? A few members on the forum that have Ohlins, KW and other brands have had no noise problems at all.

I had BC coils on my prior car and noise was definitely pretty bad. They rode good and made the is350 lackluster suspension much better but they weren't the best quality overall. I think I needed a rebuild at around 50k as well.

[Sail Boat]

In conjunction with a two-month production delay for the BC system and advice from RRT (my preferred BMW shop), I've canceled my BC order and instead ordered the KW V3 Coilover Kit.

Since I'll be unplugging and coding out EDC, I went for the cheaper non-EDC version (great way to save a few hundred $).

In regards to achieving an ideal amount of neg. camber, based on advice from my track-hound friend, I'll start with OEM strut mounts and upgrade from there... Perhaps M3 LCAs and camber plates, in that order.

Will post an install video later on!

[Dylan86]

First impressions with my KW CS's w/50 lbs lighter springs are that they're very tight, no clunks or noise from top hats whatsoever, even over speed bumps and driveways. Got rid of the famous Dinan "click". Pretty happy camper, here.

I'd definitely run the KW Top Hats over the other options.

Hoping you have the same experience!