Front end clunking/knocking - LONG. - Saab 9-5 Bulletin Board - Saabnet.com
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Front end clunking/knocking - LONG.
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Posted by Doug W [Email] (#2371) [Profile/Gallery] (more from Doug W) on Sat, 1 Sep 2018 22:08:48 Share Post by Email
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I've been chasing a front end knocking noise for months now. It's driving me NUTS. Car is an '04 9-5 Aero Wagon with 197,000 miles.

Here's a list of what I've replaced in the couple of months exceptions notoed:
Struts (Koni Active) with ALL hardware and bearings.
Lower control arms with all bushings and ball joints (eEuro Kit).
Sway bar links (Febi).
Tie rod ends. (Febi)
Exhaust (BSR).
Transmission Mounts (upper & lower - dogbone)
Engine mount - left side (Hutchinson). 9/4/17 181,000 miles.
Air Filter Box mounts.

The noise only occurs over sharp bumps. It sounds like a large mass hitting the body, like a subframe bushing gone bad. I had the sub-frame dropped and the bushings checked as well as the rear motor mount. My tech stated they were all fine and didn't need replacement. The two rear subframe bushings were done 3.5 years ago at 147k. The bolts are all torqued to spec.

The BSR exhaust initially was hitting the body. I took it to a muffler shop and they adjusted the fit. No more body rattle from the muffler but the front rattle / knock noise is still there. They said it was motor / transmission mounts. Granted those were shot so I replaced them TODAY. The vibration levels at idle are WAY down but the knocking noise persists.

The noise has been around for maybe a year but over the past four or five months it's gotten worse. Given all that's been done, what else is there? I checked the half shafts. There is play in and out but not up/down or front to back. I drive in tight circles in a vacant parking lot with no clicking so it's not the CVs. Could it be front wheel bearings? There's no telltale growling.

I checked the sway bar mounts and they're intact and fine.

On smooth pavement the car drives perfectly. The front end is tight with NO play or odd behavior and the alignment is perfect according to the shop that dropped the sub-frame and checked the bushings. I drive slowly over larger bumps like curbs into a driveway and there is no noise. Again, it's only over SHARP bumps like broken and patched concrete seams on a deteriorated road at 25 - 40 mph that produces the noise.

Any suggestions would be appreciated.

_______________________________________ '03 Aero 5Spd, Krona, 290 bhp (son's) Sold: '04 Aero Sport Kombi, Sport Tek, BSR '03 Linear 5 spd. Krona Mods, 350 bhp


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