Bilstein Strut Clunking

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Old 03-18-2005, 10:36 AM
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Default Bilstein Strut Clunking

I installed Bilstein HD struts in my '96 A6Q all around. The left front started clunking shortly afterward. Mechanic said it was a faulty strut. Bilstein sent a replacement but the same thing happened...clunking. It also sounds like it is binding when I turn the steering wheel to the left. Doesn't do it when I turn right. The mechanic has checked all the bolts several times. All okay. I've read some posts here that some struts don't fit snugly in the housing causing movement and noise. Has anyone solved this kind of problem with Bilsteins?
Old 03-18-2005, 03:28 PM
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Default Bilstein recommends you wrap the strut in duct tape...

or fill the strut housing with oil. I have no experience with either method.
Old 03-19-2005, 06:04 AM
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Default I have the same problem. Anybody had experiance with one of these methods?

should I fill tube with the greese?
Old 03-19-2005, 08:30 AM
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Default Re: I have the same problem. Anybody had experiance with one of these methods?

It was standard procedure on the 1988 Audi's to put 90 manual transmission oil into the strut housing but I have not seen this on later models.
I would rather use a shim under the cap nut which holds the shock into the strut to ensure that the shock is firmly pressed down and cannot move.
Old 03-19-2005, 09:46 PM
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Default try duct tape first (seriously)

I tried 5w50 in my 90s strut tube and it made no difference, still have the strut binding sound.
Old 03-20-2005, 08:32 AM
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Default Re: I am not aware about the nut. In my case shock just sits in the strut tube.

There must be a cap nut holding the shock in the strut tube.
And no - please don't use oil or grease. Like I said the early Audi's used this method but there must be a good reason why they stopped doing it.
Old 03-20-2005, 06:21 PM
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Default Re: Bilstein recommends you wrap the strut in duct tape...

Really! Where did you hear that Bilstein recommends duct tape?
Old 03-22-2005, 07:03 PM
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Default Re: Bilstein Strut Clunking

The reason for putting "oil" in strut housing is to facilitate the transfer of heat from the working of the damper to the outer housing.
HTH.
Old 04-11-2005, 09:12 AM
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Default Update: Bilstein clunking...

Unbelievable. The replacement strut from Bilstein also went bad. My mechanic pulled it and there's fluid all over the strut housing. None in the strut insert where it's supposed to be. This strut started making noise when first installed. Got gradually worse, over the past year, until I couldn't stand it anymore. Ordered a replacement from eShocks.com...where I bought it. I couldn't get three bad shocks in a row...could I?
Old 04-11-2005, 09:17 AM
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Default BTW: Great mechanic...

My mechanic didn't want to put the bad insert back in so he bought a new Boge Turbo-Gas shock and installed that. When the Bilstein gets here, he'll put that in and use the Boge in his '93 S4. What's it cost for that kind of service you ask? No charge. What great guy! Ted Savas, Val's Foreign Auto Repair, Haverhill, MA.
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