Suspension/caliper thud sound at low speeds

[r3d]

After I went to the track for the first time, my MY19 cupra started having some strange new noises.
When I am parking, mostly when I change from reverse to D (its a DSG) and turn the wheel, I can hear a loud thud usually from passenger side, but sometimes the driver side also. The sound is the same as if some bushing has failed. Also a strange click feeling appeared when i put my foot on the brake (just put the foot, not brake, pedal moves around 5-10 milimeters). The 'click' can be heard also.
Naturally, as the car has just 16 000 kilometers on the clock (cca. 11k miles) I went to the dealership.
We got the car jacked up and checked all the standard stuff (wishbones, bushings, stabilizers etc) and everything was tight. Only thing we noticed is maybe excessive play of calipers around the caliper sliding pins - around 1-2 milimeters left-right one both sides - a bit more on the left side. It also sounds like its transmitting the vibration to the chassis and might be the cause of the thud. I wasn't in the car at the time to confirm it.
They said its normal to have play there, but it seems excessive to them too. Also they noticed that the pads were almost worn out (the control indicator on the pad is almost touching the disc).
Can you share your stats on brake pads wear? Isn't it a bit early to change the pads considering the mileage?
I did drive hard a few times but its not that often.

We also noticed that on both sides the lower control arm bushing is really greasy but they presume its the wax leaking from the chassis. The greasy part is marked by the arrow.



Only thing they found in VAG database is that it could be dirty wheel bearing housing (wheel hub), and the manual says it should be removed, greased with high temp grease and put back. They ordered the grease and they will call me when they have it in stock to do the maintenance under warranty.

Please post if you have similar noises when parking or maneuvering at low speeds so we could locate the problem.

 

[RUM4MO]

Somebody has already posted reporting "greasy" areas near these front wishbone rear bushes - and thought that they are filled with hydraulic fluid - and so had ruptured and that was why there was some thing like grease around there - does that sound to be the same as what has happened to your car?

 

[Jake_LHX]

I actually think I have something very similar. Though I wouldn't call it Loud.

It sounds as if the Tyre clips the inside of the wheel arch at full lock, or if you slip off a little piece of rubble/stone while maneuvering. It does sound like a clunk... And only happens when I am at roughly full lock and very low speeds.

I haven't let it concern me, though further findings might change my mind on that one!

 

[r3d]

Somebody has already posted reporting "greasy" areas near these front wishbone rear bushes - and thought that they are filled with hydraulic fluid - and so had ruptured and that was why there was some thing like grease around there - does that sound to be the same as what has happened to your car?

Nope, they checked in the database, cupra ones are pure rubber, not the hydraulic type.

About the sound, yeah it is a clunk. My problem is that it wasn’t there before and now its getting on my nerves. It happens every time when I am parking out so imagine the annoyance. Its not ‘somethings gonna break loud’ but it is ‘stabilizer rattle’ loud. I am sensitive to car noises, cupra suspension on sport or cupra mode is too loud on bumps anyway, keeps me wondering if something is worn all the time. BTW this bushing on control arm seemed way too soft for a sportscar when mechanic checked it with a crowbar.

Thank you guys for replies!

Here is a bonus pic for thread followers if anyone is thinking of doing the res delete in local shop for GPF cupra, as I am.

 

[Jake_LHX]

Here is a bonus pic for thread followers if anyone is thinking of doing the res delete in local shop for GPF cupra, as I am.
View attachment 12962

I am actually. Will the local provide the replacement pipe or will they order a part in?
Do you reckon they will let you keep the res box or will they want to keep/reuse it?

 

[r3d]

They will make the pipe and remove the res box. I want to keep it to be able to put it back if I wanted to.
The problem is the stainless steel pipe of that size (66mm diameter I think) is not that easy to bend properly - most places bend up to 60mm, but the guy that owns the shop is a racer and knows people so he said he could do it. I think it will cost a lot less that the res delete part (its a piece of pipe that costs 150 pounds, come on!). He made a new exhaust for my friend's civic type R fn2 from engine to tailpipe for only 450 euros, all stainless steel, stock dimensions.

 

[Jake_LHX]

Mm the garage I am talking to have the replacement pipe as a unit to swap in, I haven't got the details from him yet as to who provided the pipe and whether itll be welded or using clamps.

I am hoping to keep the box also purely for peace of mind.

 

[RUM4MO]

Nope, they checked in the database, cupra ones are pure rubber, not the hydraulic type./QUOTE]

That was what I'd have expected it to be, but the other thread/poster claimed it was hydraulic, I posted back to say that, but after you mentioned greasy areas near your ones, I thought that I had got it wrong, Audi tends to use hydraulic mountings on the S4/RS4 well on engine mountings and maybe some others and it seems that some of their ones have contacts on them so that the driver gets a warning when one has failed! Good to know it is not an issue with Leon Cupras.

 

[Fer16v]

I actually think I have something very similar. Though I wouldn't call it Loud.

It sounds as if the Tyre clips the inside of the wheel arch at full lock, or if you slip off a little piece of rubble/stone while maneuvering. It does sound like a clunk... And only happens when I am at roughly full lock and very low speeds.

I haven't let it concern me, though further findings might change my mind on that one!

Well....my case is a bit similary. From new (now 2k miles), my Cupra R makes a soft "clac-clac" noise when turning left in medium-hard turns. Not even at full lock (i.e in a roundabout), but at low speeds (up to 70-80kms/h - 45-50mph). Almost certain is located in the right front wheel. To allow you to have an idea, is exactly the same noise (in every single wheel spin) when you have a little stone stuck in the tyre.... but i haven't!!! Is not a worrying issue, but something seems not to go well. Do you think it would be an defective marked bearing? Some simillar cases? One curious thing about the subject is that i don't a have a single noise nor on a straight line, or when turning right...

Regards!!!

 

[martin j.]

Cv joints start to make a noise as they fail, an aggressive track day hasn’t put extra strain on them?