Strange clicking/popping from rear left after suspension overhaul

[dinbirb]

Hey guys,


I’m looking for some advice on a weird issue with my 500E. I just had the rear suspension refreshed with new control arms and original springs, but the shop made a massive mistake during the process: they accidentally installed front springs in the rear. The car was sitting crazy high for a short time before they realized it and swapped in the correct ones.


The ride height looks fine now, but I’ve got this strange clicking or "cracking" noise coming specifically from the rear left whenever the suspension extends. It’s most obvious when I’m jacking the car up—every time I pump the jack and the body rises, I hear multiple clicks coming from that corner, almost like something is under massive tension and releasing bit by bit.


I’m wondering if they torqued down the new control arms while the car was sitting way too high on those front springs, and now the bushings are completely preloaded and binding up. Or, even worse, could those long front springs have overextended the SLS strut and damaged the internal travel stop or the valving?


Has anyone dealt with this kind of multi-click sound when jacking up the car? I really want to make sure I’m not shredding my new bushings or that my SLS struts aren’t toast before I head back to the shop to complain.

 

[TerryA]

Before the shop tightens up the new components the car should be settled down on the ground bearing full weight on the suspension. Then torque down all of the bolts.

If they did it any other way it will have problems.

 

[gsxr]

How did they make front springs fit in the rear? They are literally too large! Are you sure they didn't just not have SLS adjusted correctly? That would have the rear end crazy high. SLS shocks cannot overextend, hopefully there was no damage.

Anyway, yes, ALL rear arms (control arms AND the other 4 links on each side) must only be torqued to spec with the car in "ready to drive" position / ride height. This won't cause noises, but will cause abnormal (high) ride height, and will drastically shorten the lifespan of the bushings, as they will be under stress at all times.

My guess is something isn't tightened that should be. The trick will be locating it. Is there any other (more competent) shop nearby? This one doesn't sound like a place you want touching your car again.

 

[dinbirb]

How did they make front springs fit in the rear? They are literally too large! Are you sure they didn't just not have SLS adjusted correctly? That would have the rear end crazy high. SLS shocks cannot overextend, hopefully there was no damage.

Anyway, yes, ALL rear arms (control arms AND the other 4 links on each side) must only be torqued to spec with the car in "ready to drive" position / ride height. This won't cause noises, but will cause abnormal (high) ride height, and will drastically shorten the lifespan of the bushings, as they will be under stress at all times.

My guess is something isn't tightened that should be. The trick will be locating it. Is there any other (more competent) shop nearby? This one doesn't sound like a place you want touching your car again.

I just looked closer and realized the shop also forgot to install the washers on the rear SLS struts (bottom mount at the control arm). Between the missing washers on the sway bar links and the struts, the whole assembly is clicking and shifting under load

Could this be the source of the noise?

 

[gsxr]

I just looked closer and realized the shop also forgot to install the washers on the rear SLS struts (bottom mount at the control arm). Between the missing washers on the sway bar links and the struts, the whole assembly is clicking and shifting under load

Could this be the source of the noise?

Yep - could be. Need to double check EVERYTHING they tuoched and see what else was not done properly.

 

[HawkerSam]

Hey guys,


I’m looking for some advice on a weird issue with my 500E. I just had the rear suspension refreshed with new control arms and original springs, but the shop made a massive mistake during the process: they accidentally installed front springs in the rear. The car was sitting crazy high for a short time before they realized it and swapped in the correct ones.


The ride height looks fine now, but I’ve got this strange clicking or "cracking" noise coming specifically from the rear left whenever the suspension extends. It’s most obvious when I’m jacking the car up—every time I pump the jack and the body rises, I hear multiple clicks coming from that corner, almost like something is under massive tension and releasing bit by bit.


I’m wondering if they torqued down the new control arms while the car was sitting way too high on those front springs, and now the bushings are completely preloaded and binding up. Or, even worse, could those long front springs have overextended the SLS strut and damaged the internal travel stop or the valving?


Has anyone dealt with this kind of multi-click sound when jacking up the car? I really want to make sure I’m not shredding my new bushings or that my SLS struts aren’t toast before I head back to the shop to complain.

Sounds like bushings preloaded at the wrong ride height - have them re-torque everything at normal ride height. Also double check SLS links/strut for binding after that spring mixup.