Last weekend I installed my Hotchkis swaybars. The installation went off without a hitch - everything fit well and all bolts were torqued per the Hotchkis installation guide. However, I'm now getting a knocking noise from the right rear end. It occurs when braking or going over bumpy roads. It seems most exacerbated when I go over small bumps - like manhole covers or seams in the road - at 15-35mph. I'd describe the sound as a knock, thud, or heavy click.

After doing some research, it seems that others have experienced this and its turned out to be loose bolts on the sways, ungreased bushings, bad endlinks, or a bad axel. I raised the car up today and checked all my bolts - I even tightened tighter than the 40ft/lbs recommended by Hotchkis - the problem persists. I'm unable, by physically grabbing the sways or wheel and shoving, to recreate the noise.

Does anybody have any suggestions - do I go back to my stock setup and see if it persists then get warranty service, is there anything I can do to narrow down the possibilities? I'd hate to have to reverse all my work and then re-perform it, but I'll bet the dealership will blame the sways for any problems that arise.

Thanks in advance!

 

My first instinct was ungreased bearings... did you use the grease that was provided from the kit (non-lithium based grease). Lithium based grease will definately be the cause of the noise...

 

Yes - I used the grease that was provided. Maybe I need more grease? I thought that lack of grease caused a crunching sound as opposed to this clunk, so I've been assuming that it's not the grease. I definitely coated the inside of the bushings with grease...maybe not liberally, but definitely a coating.

 

I've seen other posts recommending lithium.

What is the best type to use?
They don't give you much with the bars.

 

>Lithium based grease will definately be the cause of the noise...

No, lithium grease is one of the best lubricants for bushings. I've used
lithium grease on my G35C and cars in the past plus my buddies, etc.
etc. NEVER got any noise.

 

Did you have to undo any part of the exhaust to do the install?

 

Not for the sway bar bushings. Lithium grease can wash out with water and should not be used. Even in the directions it specifically says to use their grease or any other grease that is non-lithium based. Check it out yourself

http://www.hotchkistuning.com/bin/in...ions/22404.pdf

 

GSedan35 - I was replacing my mid-pipe with a 350Z mid-pipe at the same time, so I happened to have the exhaust off when I installed the sways. Any ideas on my knocking noise? You've got the most suspension experience of anyone I know...

 

You're right. What the hell was I thinking?! What the hell did I do to my
cars?! hehe. It won't wash out unless the swaybar has no collars to
hold them in place. In that case, any grease will dry up. On the G35C,
how the heck are you going to wash out with the engine cover on? For
rear, that bracket is away from the wheel wells... Only an undercarriage
wash solely aimed at the middle of the chassis *might* get it wet. They
might be referring to the RSX install as you linked onto your post.

But, since it came with grease and you used it, you did the right thing.
If it didn't come with lube, I would still recommend lithium grease to
anyone that might be getting creeking. Your problem sounds more
involved though... hope you find a cure for your noise.

 

The collars need to be installed even if they are not the source of the problem. Most of us after a few thousand miles that have looked have seen the front bar shift severely to one side. I had the clunk and then tightened those babies as hard as they would go. Air tools wont get them tight enough. Torque the bolts hard and then see what happens and then take a look at the quite inexpensive solutions to the missing collar issue.

 

wickedg35-
btw, just do a quick search on "white lithium grease" and most of them will tell you
how repellent they are to weather including water... if you don't believe hundreds of
thousands of people that use it.

 

You mean, G35 coupe mid pipe, right? The Z mid pipe is too short. Since I seem to recall a sedan owner that did the mid pipe swap mention a clearance problem with the coupe's premuffler. I'd grap the tail pipe and shove it around and see what happens. Then I'd climb under the car to right under the premuffler and see what happens if you shove upwards quickly.

You did mention that you rechecked all bar attachment points, correct?

 

Actually, it is a 350Z pipe. Both the Coupe and Z mid-pipes are too short and there's an extension available to close the gap. However, I found my Z mid-section from Z-car Garage in San Jose. They actually replaced the short pipe with a new one that fit perfectly. It sounds great too!

I hadn't thought about the exhaust causing the noise - I'll definitely give that a good shove tomorrow and see if it's to blame. Thanks!

 

I know that certain lithium grease is water repellent, but this is for the average Joe who would pick up a bottle of any grease at a car store (most of which are lithium based). And water can definately get in the underbody, especially running through heavy puddles and 1+ inch rain....

 

harder to fine one that isn't.