Slow Speed Knock/rattle In Rear End Of Fg

[phat_stak_tipa]

Ok so bilstein knock had been sorted....hopefully for good!

This is how shock should look,

Oh yeah I needed a 450mm breaker bar to undo the 15mm top nut!!!

I also undid the shock mount on the body that has 4 10mm bolts, they were easy to undo thankfully!

I left the bottom bolt in mainly due to the fact I couldnt undo it as I didnt have the right socket...

This is how the the other side closest to the diff looks.... As you can see there is 3 grooves!!

I got the dremel grinder out smoothed out the grooves, not a great job....

So I greased it all up and put it back together......AND it still knocked!!!!!

Got home again and took it apart, and turned the shock mount around, so the smooth part was now closest to diff, and the part with the grooves facing me, packed more grease into the shock bolt hole and went for a drive and NO NOISE!

I think it will come back, but if it does il be abit more heavy with the grinder and see what happens, maybe the grease has 'cushioned' things maybe turning the shock 180degrees helped not sure but it now is ok, thank f*ck for that!

Edited 26/07/14 07:19 AM by phat_stak_tipa

[phat_stak_tipa]

So between ello678 and myself we have been chatting about this issue, there has been alot of mucking around due to the fact that the noise continues to come back.

ello678 has had a top bilstein bush replaced and the noise came back, he also tryed a custom bolt that was slightly thicker but this has not worked either, after both of us being in touch with heasman suspension (bilstein reps), the foreman who seems happy to help (unlike one of the other employees) has now decided to make some even thicker bolts and see if that works.

I have played around and had the most success with having the top hole and bolt packed with grease, but the noise came back, so my theory based on all the info is........

The factory bolt must be just a touch too small, and I believe the alloy? Of the bilstein is very soft and the bolt eventually wears the hole out, elongating it and causing it to rattle around no matter how tight the bolt or mount is.....

So hopefully for all that are having this issue thanks mainly to ello678 we will have a fix.

[boost69]

Not sure if it's relavent...I have BF Mark II XR6T with Bilsteins allround...the car had that rear end knock before the Bilsteins, and continued to have it after the Bilsteins.(no effect on the knocking)

Also have an FG XR6T, and that has the same rear end passenger side knock...(there are times when this really gets on your nerves, especially when your driving on Parramatta Rd) I still have warranty on this car, and it has gone into Ford numerous times for this issue...the cradle has been pulled out numerous times too...all diff bushes have been replaced...in the end they even replaced my rear passenger side shock..and they still can't figure it out.

They acknowledge that the knock is there...but they can't find what is physically causing it...

Not to state the obvious, but this an inherent problem with the B and F series rear end set up...(even just looking at it from a diff bush perspective...let alone the knocking)...

It might be out of left field, but I have heard if the wheel hub isn't to exact tolerences, then that extra slack can cause a knock over mild bumps...(I realise I'm clutching at straws here...)

Edited 05/05/15 10:00 PM by boost69

[Ralph Wiggum]

Are you guys aware of the TSB to fix the knock/click cause by the length of the spring retainer tab in the upper spring seat?

[phat_stak_tipa]

Not sure tsb is relevant to the bilsteins, never had the knock before the bilsteins went in, and had kings in with standard shocks for ages too, no noise......

[boost69]

Not aware at all...surprised the Ford dealer didn't mention this also...so basically I should give the dealership a call and mention this?

[08G6ET]

I'm in the same boat as ello678 and phat_stak_tipa. I have bilsteins installed on my G6ET with stock Springs and the knock is there, predominantly on the rear left side.

I spoke to Heasman and got the same spill as phat_stak_tipa.

There was no knock when the stock shocks were in.

I haven't had a chance to pull them out at home, but hoping to in the next couple of days. One thing I want to try putting some thick tape or felt type material on the bolt that sits in the top shock eye and see if that makes a difference.

Also, what is tsp?

Edited 08/05/15 03:17 AM by 08G6ET

[boost69]

Technical

Service

Bulletin

It's a memo that goes around to the Ford workshops letting them know of an inherent problem, and how to go about fixing it...(Like the handbrake issue on the BA Falcons).

Though the bulletin usually says it only should be fixed if the customer complains about this issue...

Edited 08/05/15 04:38 AM by boost69

[phat_stak_tipa]

So have the shock out of the car, I think the the non threaded part of the top shock bolt is not long enough, I.e too much thread is inside the the top mount and is causing a rocking and also I have thread grooves in the top shock mount which may be causing the grooves and bolt thread to rub together, so eventhough its highly ghetto, il try what 08G6ET suggested by taping it up and see how we go fingers crossed!

[phat_stak_tipa]

So I didnt go ghetto, I picked up a new longer bolt high tensile, 90mm is all bunnings had but the non threaded bit was longer, so to stop the thread running out I packed it with some washers 5 x m12, did it all up and test drove.

Still have a slight knock that is possibly due to the shock eye/bush not being completely uniform but there is no more rattle/ratcheting sound, so I am happy, if at any point it gets worse il have another go, but now at least we have found out what it is.