knocking sound front suspension

[LiamO]

Ended up with a knocking sound coming from the right front suspension (D4) toward the end of the D3/D4/RRS 4WD Weekend in Lithgow on Sunday. No issues when back on the tarmac on the run home but knocks again when driving over small bumps/potholes. I’ve jacked it up but there’s no visible damage to the suspension/ball joints/control arm etc – any ideas?
BTW – Thank you TerryO and George for a great day around Lake Lyell

[Bushie]

Never looked under a D3/4, but loose shock absorber (worn rubber) ?


Martyn

[kingo]

My RRS just developed a knocking sound over small bumps and just after a weekend of 4wding, found to be the sway bar bushes. Was told they weren't too bad and could wait till the next service, but as I found it annoying, had them replace anyway. A few hundred to fix, much cheaper than lower arms, so better result than expected.

[LiamO]

Thanks Bushie. The D4's got air suspension which is operating correctly and there's no visible damage there either. I suspect it may be a steering arm but will leave that up to the experts on this forum :) Hopefully not too expensive to repair please!!

[SimmAus]

Ended up with a knocking sound coming from the right front suspension (D4) toward the end of the D3/D4/RRS 4WD Weekend in Lithgow on Sunday. No issues when back on the tarmac on the run home but knocks again when driving over small bumps/potholes. I’ve jacked it up but there’s no visible damage to the suspension/ball joints/control arm etc – any ideas? BTW – Thank you TerryO and George for a great day around Lake Lyell

This is really creepy - I've got exactly the same problem after that weekend! Mine has around 40k Kms on her at the moment and a noise from front right also!!! Let me know what you come back with - I have to wait a while then send it in for a pre end of warranty check up!!

[Geedublya]

Lower control arm bushes are probably the most likely suspect. I'm just about to order new arms from the UK to fix mine.

[AnD3rew]

Lower control arm bushes are probably the most likely suspect. I'm just about to order new arms from the UK to fix mine.

Sounds like it to me too, same thing happened to me about 18 months ago after an offroad weekend.

[Redback]

While you are having the lower control arms looked at, either by you or your mechanic, check the connects from the sway bar, the top and bottom nuts can come loose(so I found out) I had this exact issue, after I had my lower control arm bushes replaced, we went out driving and when the weekend was over, I notice a slight clunk, which got worse over time, top nut on the sway bar connect was loose, tightened it up, no clunk.

Baz.

[Tote]

Clunks from the front roughly in the order I have sorted them:
Lower control arm bushes worn
Rack ends or tierods worn ( easy to check for steering play )
Rubber mounting bushes for sway bar
Links for sway bar

Clunks from the back:

Sway bar mounting rubbers
Sway bar links
Rear castor rod ends
Maybe bushes but mine seem OK so far.

Regards,
Tote

[AndyG]

Knock knock
Who's there
Cyclist from Lithgow

[Epic pooh]

In addition to what tote has said, I have also done lower steering column (knock/ rattle) and upper front control arms (slop). I'd say the first place to look would be the inner bush on the lca but this so very hard to diagnose with the vehicle on the ground.

[Ozzy119]

Possibly the ball joint in the lower control arm. Was told these have been a problem for some time with a number of replacements made to fix error. About to have mine changed.

[SimmAus]

Mine has been fixed. :D
Lower control arm and ball joints replaced under warranty (vehicle has 40k kms) and coming up to 3 years.
Cheers

[LiamO]

Mine is still in the garage having the gearbox replaced (Gearbox Error) and they tell me that the 'hydro bushes' was causing the knock. All fun & games owning a D4!!

[AnD3rew]

I think I just dodged a bullet. I am going on holidays to the Sunshine Coast in a couple of weeks and at the last minute I thought I should just put it in for a quick service before we go.

Turns out the Front driver side ball joint was totally shot and they said it was unlikely to have made it to Brisbane. There was really no noticeable symptoms when driving it.

Wonder what makes just one of them on one side just go on its own? You would think thy would wear left and right at roughly the same rate, but apparently no play at all on the left side, but wobbly all over the place on the right.

[Ozzy119]

Unfortunately I didn't dodge my bullet, just out of warranty. Exactly the same issue though, front driver side.

[shorty]

Andrew & Ozzy,

Roughly how many kms?

Matt

[AnD3rew]

Andrew & Ozzy,

Roughly how many kms?

Matt

87,000 for the ball joint. Have previously replaced the front control arms at about 60,000 I think, maybe a bit less.

[kenthead]

don't know if i'm stating the obvious here but it'd be worth checking the wheel bearing aswell. Mine developed a little clunk and that was the culprit.

[irondoc]

I accidentally went over a gutter at speed the other day. knocking noise from the front ever since.

went to LR, replaced lower control arms under extended warranty - car was 3.5 years old with Allianz warranty..."just paid for itself...."

cheers
lucas

[Tassiefender]

Ended up with a knocking sound coming from the right front suspension (D4) toward the end of the D3/D4/RRS 4WD Weekend in Lithgow on Sunday. No issues when back on the tarmac on the run home but knocks again when driving over small bumps/potholes.I’ve jacked it up but there’s no visible damage to the suspension/ball joints/control arm etc – any ideas?
BTW – Thank you TerryO and George for a great day around Lake Lyell

I just replaced the lower control arm bushes after experiencing the exact same (together with a noticeable clunk after a week of hoping it would disappear...) Did the trick. No more knocking.

[crawal]

Same here , just picked up d3 with new bushes , WOW what a difference :):)
Got rid of rattle in the back it must have transmitted through the car .

[Modelsp]

Ended up with a knocking sound coming from the right front suspension (D4) toward the end of the D3/D4/RRS 4WD Weekend in Lithgow on Sunday. No issues when back on the tarmac on the run home but knocks again when driving over small bumps/potholes. I?€™ve jacked it up but there?€™s no visible damage to the suspension/ball joints/control arm etc ?€“ any ideas?
BTW ?€“ Thank you TerryO and George for a great day around Lake Lyell


Just had mine inspected under used car warranty,,NSW,,requires both lower wishbones replaced for that same low speed knock,usually over speed humps or gutters at low speed10>15k's,,also had loose sway bar mounts,,will have some video taken by the mechanic on Monday. inner control arm bushes almost completely gone.very interesting video.
also has a knock in rear end like the diff is winding up,then a clunk noise,,,very much like the CV joints in the old Mini's.

[LandyAndy]

I just had the "Hydra Bushes" done under warranty,35000km,started making noises in extended height at 27000km.
Easy way to check,put it in off-road height in a carpark and drive slowly over the larger speed humps at a 45deg angle.The short sharp speed humps didn't seen to set mine off.
I would be doing this on a monthly basis if you have warranty;);););););)
Andrew

[LRD414]

I'm booked in for inspection by the dealer in one week. Same knocking as has been reported by many and exactly as described by Andrew. Mine's at 52000km / 2yr but I started hearing the knock a bit before 50000km.

Much more noticeable at off-road height and over rough terrain.

Cheers,
Scott

[LRD414]

I'm booked in for inspection by the dealer in one week.
Same knocking as has been reported by many and exactly as described by Andrew.
Well that was a good surprise .... both front LCA hydrolastic bushes not only diagnosed but also replaced and wheel alignment same day.
Under warranty at just over 2 years and 54,000km.
Dealer servicing often cops a lot of flak but in this case they have gone the extra mile. I was expecting a return visit for the work to be completed.

I also discussed future options with the service manager, who indicated that there are OEM sourcing alternatives he can access to bring the cost down.
I will be investigating the home bush pressing versus 2nd set of LCAs as a spare set to rotate onto the vehicle when the time comes.

And for reference, this thread has good details regarding these bushes that helped me to be well informed for this:
http://www.aulro.com/afvb/l319-discovery-3-4/219785-lower-control-arms.html
https://www.aulro.com/afvb/images/imported/2016/11/957.jpg

It might be my imagination but the vehicle feels tighter/sharper over small bumps.

Cheers,
Scott

[LandyAndy]

I'm starting to wonder if they aren't strong enough,too many failing at low KM,and I know mine has done no ROUGH off-road work.
I do admit to using the accsess height on every stop,mostly whilst on the move.
Andrew

[BMKal]

Mine lasted well over 100,000km before needing replacement. Maybe I drive like an old granny (my brake rotors and original disc pads also lasted over 100,000km).

The dealers in Perth told me that there was some movement in the LCA bushes before I went to Tassie earlier this year, but said that they would be OK until after I got back. At that time, I had not noticed any knocking / movement. In fact, the only time that I picked up on anything unusual in the front end was when driving onto the Spirit in Devonport on the way home (the ramp onto the boat is very corrugated).

After getting home, I did notice the occasional clunking over the speed humps in Bunnings car park that were not usual. I had used the vehicle with raised suspension a bit in Tassie, but no unusual noises or movement. Anyway, I had the complete lower arms replaced by the dealer at the next service after we got home (and had an oil leak from the transmission repaired at the same time) - and the only problem I've had since has been a minor coolant leak, which I fixed myself at home. :D

[LRD414]

Mine lasted well over 100,000km before needing replacement.
Maybe I drive like an old granny (my brake rotors and original disc pads also lasted over 100,000km).
Have you done a lot of corrugated roads Brian? And towing?

There does seem to be a wide variance of km's achieved looking at the reports on here over many threads.
But I don't think there's a design issue. These bushes can be expected to do a lot.

Cheers,
Scott

[BMKal]

Yes - a fair bit of corrugated dirt roads in its time Scott. No real towing to speak of though, other than lightweight garden variety trailers, although sometimes with up to a couple of tonne of firewood on board - but only locally and relatively short distance, mostly on bitumen.

Up until I stopped working down in Perth, I was doing a LOT of long distance fairly high speed runs. 1,200 km round trip just to go home for the weekend. :D

This would have been what put the vast majority of the km's on the clock in my case. Certainly never had any problem at all in justifying more than 90% of the km's as "work related" for the tax man. On top of that, the Disco has been across to Tassie twice now, and across to SA for Melrose once. Have done a bit of off-roading during those trips, but nothing compared to the km's put on it on the bitumen on the way across and back.

But in general, I've always had good, reliable and long life out of any vehicles I have. I suppose it's partly the way I drive them, and also the way I clean / service / maintain them. Even company vehicles I've had on mine sites were usually seen as among the "better" vehicles on site, and there was never any shortage of people bidding to buy them in the cases where the company offered them for internal sale.

Of course, I'm typing all of this with one hand, while the other hand is firmly touching the wooden desk that I'm sitting at. :p:p:p

[PerthDisco]

Mine lasted well over 100,000km before needing replacement. Maybe I drive like an old granny (my brake rotors and original disc pads also lasted over 100,000km).


I'm at 80,000km on second set which were replaced around same time. No untoward knocking or behaviour. Mix of on and off road like BMKal. 99% at standard height in a time sense.

I similarly drive like a granny. Always complete rest before gear change etc.

[Jaybee]

I accidentally went over a gutter at speed the other day. knocking noise from the front ever since.

went to LR, replaced lower control arms under extended warranty - car was 3.5 years old with Allianz warranty..."just paid for itself...."

cheers
lucas

My timing is similar, except that Allianz refuse to cover it under their extended warranty. They cite that bushes. hoses etc are not covered. So in this instance, that makes the Allianz extended warranty a great waste of money.

D4 MY12 with 39000km was in for it's 4 year service when the shop picked it up. I hadn't even noticed any knocking. Also to make matters worse, LR reckoned that they would not have been covered under the new vehicle warranty even if they were knocking within the original warranty period of 3 years. I found that hard to believe. Cost quoted by LR to repair is $1970. Does anyone have any suggestions as to where else to get them replaced in Brisbane and how long can I drive on them before they become a safety or breakdown hazard.

Also, as the D4 is now out of warranty, does anyone have suggestions as to a good service shop in Brisbane that's more affordable than LR?

Jaybee

[LRD414]

D4 MY12 with 39000km was in for it's 4 year service when the shop picked it up. I hadn't even noticed any knocking.
Also to make matters worse, LR reckoned that they would not have been covered under the new vehicle warranty even if they were knocking within the original warranty period of 3 years. I found that hard to believe.
That's not my experience. As mentioned in my earlier post here, bushes replaced under warranty at 2y/52,000km travelled.
Plus a few others in this thread have had them done under warranty too.


Cost quoted by LR to repair is $1970. Does anyone have any suggestions as to where else to get them replaced in Brisbane and how long can I drive on them before they become a safety or breakdown hazard.
Also, as the D4 is now out of warranty, does anyone have suggestions as to a good service shop in Brisbane that's more affordable than LR?
I have read good things about Greg Tunstall and also SBL Automotive but haven't actually used either myself.

I was quoted $1500 by dealer for bush replacement outside warranty.

Regards,
Scott

[Jaybee]

That's not my experience. As mentioned in my earlier post here, bushes replaced under warranty at 2y/52,000km travelled.
Plus a few others in this thread have had them done under warranty too.

I have read good things about Greg Tunstall and also SBL Automotive but haven't actually used either myself.

I was quoted $1500 by dealer for bush replacement outside warranty.

Regards,
Scott

Thanks Scott

Yes I saw that others on this thread had them replaced under warranty. Perhaps it was difficult for me to get an accurate response as my vehicle was out of the factory warranty. At the time I was trying to get LR to ascertain whether Allianz would cover the replacement so perhaps LR didn't want to commit. I've also found that since the LR dealer has relocated, due to growth and expansion, that I'm now dealing with staff who are far less experienced than was the case 2 or 3 years ago.

The quote from LR was $1970 for replacement of both lower control arms, much higher than your $1500. I might need to send you in next time to do the bargaining.

I'll look into your suggestions for an alternative, however, as I'm in the west and both repairers are a way out of town I'll also review Comet Automotive in Albion.

Ciao

Jaybee

[Plane Fixer]

The bushes are not expensive and can be replaced on the vehicle with the right tooling.
I bought new arms, fitted them and have rebushed the originals, including the ball joint for good measure. Certainly for far less than quoted price as I fitted them myself and had a wheel alignment done after.
Be aware sometimes the clunk can be from the swaybar bushes which I also replaced at the same time; they are very cheap.

[Jaybee]

The bushes are not expensive and can be replaced on the vehicle with the right tooling.
I bought new arms, fitted them and have rebushed the originals, including the ball joint for good measure. Certainly for far less than quoted price as I fitted them myself and had a wheel alignment done after.
Be aware sometimes the clunk can be from the swaybar bushes which I also replaced at the same time; they are very cheap.

Okay, that sounds great but not being too mechanically minded I'm not sure what tools I need or where to support the vehicle and wheel struts whilst replacing the control arms so I might just have to leave it to the experts. Otherwise, are there any tutorials you know about? It doesn't look to hard but it's knowledge that makes it easy and not knowing that makes it time consuming and hard. Where do you buy the replacement arms from? Do they have to be OEM or are there others that fit?

Mind you, perhaps it's easier than I think. After all, I fitted a Mitch Hitch on Saturday after following Scott's informative posts on this forum. Thanks Scott.

Cheers Jaybee

[Modelsp]

Just got mine back today,,in Wollongong.
Local repairer,,cost $418 each for control arms complete new.
4 hours labour@$100hr.
Wheel align $50
genuine parts.
sorry forgot to mention ,12/08, D3@99K,k's.
i think they're the same part numbers as D4.
should give you something to work with when checking prices.
cheers
Paul

[Jaybee]

Just got mine back today,,in Wollongong.
Local repairer,,cost $418 each for control arms complete new.
4 hours labour@$100hr.
Wheel align $50
genuine parts.
sorry forgot to mention ,12/08, D3@99K,k's.
i think they're the same part numbers as D4.
should give you something to work with when checking prices.
cheers
Paul
Now that level of pricing is more like it.
Parts $418 x 2
Labour $400
Alignment $50
Total $1286
I can't see how the LR dealer/repairer can charge $1970 for the same job. I've called another repair shop for a quote to compare and if I can find someone reasonable will no doubt take the D4 to them in future for all servicing.

[Tombie]

Parts $836 [emoji6]

Adelaide dealer does the arms fitted for $1200 [emoji106][emoji56]

[Jaybee]

Parts $836 [emoji6]

Adelaide dealer does the arms fitted for $1200 [emoji106][emoji56]

It looks like they do a better deal all round as I bought my D4 from them and they shipped it to Brisbane for a better deal than I could get locally. It's true that the internet can create a more level playing field.

Cheers Jaybee

[Jaybee]

Found this extremely helpful post on replacing the lower control arms on this forum, thanks Ean

http://www.aulro.com/afvb/projects-tutorials/161206-how-d3-lower-front-suspension-arms.html

Also got a quote from Comet Automotive for $1230.25 using genuine parts and $1156.10 using OEM parts, both of which are considerable better quotes than the LR Dealer so I know who will be servicing the D4 in future.

Cheers Jaybee
D4 MY12

[Tombie]

And that is why doing them on vehicle and replacing the bushes in situ is so much easier [emoji6]

No undoing drive shafts, no pulling brake callipers or hubs off...

[Guppy]

Any suggestions for Melb metro workshops from experience with this issue?
Dealer also quoted close to $2K

Thanks
Guppy

[Jaybee]

Any suggestions for Melb metro workshops from experience with this issue?
Dealer also quoted close to $2K

Thanks
Guppy

Have a look around for a Specialist European Repair shop or a British Motors Specialist as they will have the experience and be able to get genuine parts. Otherwise, I'm sure there would be a number of good repair shops in Melbourne that could get the parts and do the job. After all, lots of people on this forum have done the work themselves.

Initially I had difficulty weaning myself from the LR Dealer but with the D4 now 4 years old and getting a quote from the Dealer of $1970 to replace the arms did it for me. The European Auto Specialist (in Brisbane) quote was $1230, big difference.

Cheers Jaybee

[Tombie]

Gotta love the SA Metro dealer!!!

Cheaper than East Coast Indies [emoji41]

[l00kin4]

Picking up an old thread here as I've been chasing down a bit of a knock in the front for a little while now and want to replace the anti-roll (sway) bar mounting bushes.

Struggling to get at the top nut on the passenger side... Have a deep offset ring spanner but not quite deep enough.

Would anyone be able to tell me exactly where they were able to procure a deep offset wrench with which they actually did this job ? Unfortunately most places selling them don't actually specify the offset and trial and error is not how I'd like to do this.

Or is there another method to access that top nut ?

Thanks,
David

[DiscoJeffster]

Picking up an old thread here as I've been chasing down a bit of a knock in the front for a little while now and want to replace the anti-roll (sway) bar mounting bushes.

Struggling to get at the top nut on the passenger side... Have a deep offset ring spanner but not quite deep enough.

Would anyone be able to tell me exactly where they were able to procure a deep offset wrench with which they actually did this job ? Unfortunately most places selling them don't actually specify the offset and trial and error is not how I'd like to do this.

Or is there another method to access that top nut ?

Thanks,
David

I undo the three diff mount bolts, then you can flex it out of the way on its rubber bush using a pry bar or something else, then I can get a normal spanner into the bolt.

[Eric SDV6SE]

Or a 24mm crow foot spanner end gets there as well, however hard to get to the required torque value. When I did mine, that bolt just went VFT.

[l00kin4]

Digging up an old thread here but I still have a persistent but inconsistent knock which I can feel through the steering although I'm not 100% it is in the steering.

It has gotten very gradually worse over time and persisted through having LCA bushes and ARB bushes replaced.

It is a clunky rattle that feels smaller than LCA bushes.

Doesn't necessarily manifest when going over bumps - occurs sometimes even on flat concrete in a carpark. Mostly only occurs when turning left.

So far I nor my indie have been able to replicate it.

Thinking lower steering column based on previous comments in this thread...

Open to any other suggestions.

Thanks,
David

[PerthDisco]

When my car was new and still in factory warranty I had an occasional clunk driving around after cornering before I knew anything about LCAs at about 50,000kms. Under warranty LR replaced something in the steering column which fixed it. Assume was the lower uni joint. LCAs were done later around 90,000km for first time.

As well as being ready for 4th set of LCAs and probably all arms and air springs I now have a loud groan / creak evident when reversing at near full lock particularly if car has been sitting that I’m wondering what that could be? Steering arms all tight and new sway bar bushes and links.

I do have new in and out tie rods ready but there is absolutely no wobble in old ones except the ball joint movement.

Sharing one solution with a new question.

[Eric SDV6SE]

If you can feel it through thr steering, it would have to be around front drive shafts. CV joints or steering tie rods and their ball joint come to mind.

[RANDLOVER]

I've heard of a case where someone clipped a kerbstone in a Rangie (but I think this could apply to a Disco) which shifted the sway bar over a bit, the rubber was a bit tight so held the sway bar in the new position, which then upset the suspension geometry causing knocking.