L322 Tearing through front suspension

[flyboy]

Hi...sorry for the long post, trying to track down a long running front suspension noise!!
Over the last year or so, my 2004 3.0TD has had creaking/squeaking/knocking through the front suspension, mainly whilst slow manoevering (car parks, turning into driveway, etc).
A couple of months ago, I replaced the front upper and lower suspension arms (with Delphi), the inner and outer tie rods (genuine) and the drop links. I also tightened up the sway bar bushes. The front struts are about 2 years old (Delphi). I then had the wheels aligned.
So, after all that, things drastically improved (say 90%) and I still got an occasional knock but figured that was probably sway bar bushes needing replacement. When I replaced everything, the only wear I saw was the rubber bushes on the upper arms were split.
Things lasted about a month and are now back to the original creaking/knocking ghastly sometimes almost a slight crunching noise whilst turning. Intriguingly I've noticed both front upper suspension bushes are again, completely torn. Does anyone know of something that could have caused it? The only things left to replace is the steering box, or the struts, or sway bar. Would either of these, if worn, put excess pressure on those bushes to cause them to fail prematurely?
The car has done just under 200k and I've had it for 10 years so.
Any help greatly appreciated. Thanks in advance!

[chaybra]

seems to be the ongoing issue with these cars.

I have had the knock for about 2 years now, replaced everything but the steering rack (and im sure this is where its coming from) there is noticeable play in the rack and noise....its on the list to do.
the larger bushes on the subframe tear very often on mine (lifted and bigger offset rims) and i will be replacing with solid superpro ones shortly and hope that goes well. but im sure this will just cause the smaller one to perish quicker.

[Strangerover]

seems to be the ongoing issue with these cars.

i will be replacing with solid superpro ones shortly and hope that goes well. but im sure this will just cause the smaller one to perish quicker.

Mine don't seem to last very long either, there's a very big range of movement the bushes must accommodate- I wonder if that's what causes it. I had a couple of guys at the Vic 4WD show tell me my lowers were torn, they noticed huge movement as i drove past the gate they were managing. Took it back to Ritters for a proper inspection, turns out they were fine; they just LOOK completely ripped, I think there's some hollow sections in the one that mounts to the subframe that gives this impression. Anyway, I'd be interested to hear what difference the solids make to ride & compliance. They're solid poly, right?

[flyboy]

Thanks guys....Strangerover you may be right about it 'looking' torn, rather than actually being torn.
I've booked the car in to be looked at by my mechanic, since I've just moved and the car is now having to live on the street so I can't pull it apart 😩. My gut feel is it's the steering box. I can't get it in until the end of May so will report back on the result...

[Roverlord off road spares]

Mine don't seem to last very long either, there's a very big range of movement the bushes must accommodate- I wonder if that's what causes it. I had a couple of guys at the Vic 4WD show tell me my lowers were torn, they noticed huge movement as i drove past the gate they were managing. Took it back to Ritters for a proper inspection, turns out they were fine; they just LOOK completely ripped, I think there's some hollow sections in the one that mounts to the subframe that gives this impression. Anyway, I'd be interested to hear what difference the solids make to ride & compliance. They're solid poly, right?
this is what the upper bush RGX00080 looks like.
123104

[Strangerover]

My gut feel is it's the steering box.

I too replaced most bits excluding the rack when chasing down what had become a very alarming knock, most evident on things like speed humps, driveways etc.
Changed all control arms, didn't fix it. Changed out apparently ok ball joints and voila, knock 99% gone.

[Tombie]

Just a quick one; When you're tightening the arms up after replacing the bushings - Are you lowering the vehicle to the floor and doing them at standard ride height?

[flyboy]

After a second look, I'm certain mine have torn again (photo).
I definitely tightened the lower arms with the weight back on the wheels, but now am doubting if I did that with the upper arms 😩.

[chaybra]

I should point out, the bush should only be attached in 2 spots opposite each other, the others are limiting stops and are not attached. when they are torn, the center will basically fall out when removed.

[chaybra]

Finally got the new SuperPro solid bushes in the front. old ones were close to being completely separated

See attached

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[Blade74]

What will be the negatives of using them Chaybra?
Harsher ride?
Less movement where required?

[chaybra]

What will be the negatives of using them Chaybra?
Harsher ride?
Less movement where required?

they feel pretty good so far, but i suspect the smaller inner bushes will go soon as a result, ill them change them for the super pro ones as they have a lifetime guarantee