Hi, first post on the forum!

I've had my 500S 1.2 for two years, and about a week ago it started making a clunking noise from the front left wheel arch.

I did some investigating and found that the shock dust cover is missing a piece, the skirt at the top of the cover (shown in pictures)

As a result the whole shock cover moves up and down the shaft loosely, whereas the right hand shock does not, it stays firmly in place at the top.

Does anyone know what this piece is called? I cant find it anywhere, all I can find is the boot.

I don't think its the jounce bumpers making the noise as some have suggested on other posts.

Also, is the shock dust cover (the black tube in the pic) meant to be loose on the shaft at the bottom?

Has anyone got photos to hand of their front shocks for me to make a comparison?

Im in third year warranty and my dealer (Ancaster Fiat) have been a nightmare in the past.

Will upload pics tomorrow.

Thanks!

I'd be slightly concerned about how or why a piece of the front strut is missing? Did you buy this car from new? If you did, unless something has physically broken away, I can't see that a piece would be missing. Something may well be broken at the top end though.

As for the dust cover, yes, they are loose at the bottom end, i.e. they aren't secured to anything.

Concerning your warranty, don't be tied to the dealer you bought the car from, go to another one if within reasonable travelling distance and get the car looked at there if you're not happy with your local dealership. I used to do this all the time, no loyalty on my part to one particular dealership from me I'm afraid and never stopped any warranty work being carried out, even in the third year. And on that, get your first MOT done 30 days before it's due, i.e. in the last month of your 3rd year warranty, that way, if the car fails on anything which might be warranty related (though you have to check Fiat's wear/tear policy carefully) you can get it fixed by the dealership FOC.

Thanks for the reply frupi, it's just the cap of the dust protector sliding up and down, it's a little bit of plastic nothing serious, it's just making an annoying noise!

My previous 500 had the same problem. The lower, wider part of that white plastic thing was no longer there. I have no idea how it disappeared.

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AGH1965 said:

My previous 500 had the same problem. The lower, wider part of that white plastic thing was no longer there. I have no idea how it disappeared.

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that's exactly it! did the white bit start sliding up and down on the shaft?

Whoever answers next, please be very careful how you answer........:devil:

frupi said:

Whoever answers next, please be very careful how you answer........:devil:

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Haha... at least that's taken my mind off a potential suspension "mishap" into a wall ?

I think you might be seeing a symptom of the fairly-common top mount failure. All jokes aside, can I suggest removing the top mount nut (the rusty one) under the bonnet, with the weight of the car on the suspension - as in, not jacked up - copious quantities of WD40 required.

Then, after removing this first nut and the rubber-covered washer, carefully check that the now-exposed second nut is still tight. Again, only do this with the car's weight compressing the spring. I suspect that it may have worked loose (along with wear in the top mount rubber) and the movement of the shock absorber spindle in the (steel centre) of the mounting is causing the clonk, plus has also caused the breakage of the plastic bumpstop collar.

If the second nut (under the washer) is found to be less than fully tight, I suggest removing the strut and disassembling it to replace the top mount and the bump stop (with protective gaiter). This requires spring compressors and, to be clear, under no circumstances remove the second nut without compressing the spring safely first.

You might elect to remove the strut from the car (by raising the car, undoing the first nut/washer on top, the two bolts at the bottom bracket, and the brake hose) and take it to someone with the appropriate tools to disassemble the strut. EDIT: especially since the car is under warranty; sorry I didn't understand that when I wrote this.

I'd be surprised if it is just the moving plastic and rubber boot/bumpstop that creates a noticeable clunk, as such lightweight items are generally not the source of such sounds. That's why I think it's a symptom and not the cause, and it needs more investigation, for safety

-Alex

billypaulmason said:

sliding up and down on the shaft?

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But seriously, I didn't hear any 'clunk'. The problem on my (previous) 500 was discovered after one year driving with Novitec 40 mm lowering springs. I guessed that these could have influenced the breaking of the white plastic part.

Hi guys!No need for a new thread for this, so I would like you to meet my new mate, Clunk, he comes with me everywhere I drive my Doblo 263. Obviously at first I thought that I need to replace the drop-links, as it is very similar, but it turns out not to be the case.
No play in the wheel, ball joints, steering, rubber bushes seem fine, drop links changed. Buddy Clunk still getting louder. I'm thinking strut mounts next. What do you think? Check out the video for the noise in question:

[ame]https://youtu.be/PluAR4hmdNA[/ame]

Thanks!

Ours does this and I think it must be coming from the joint at the end of the steering rack and/or the steering rack mounts as these were both identified in the mot as advisories.
I replaced one of the top mounts a while ago in an effort to silence the clunking but no joy.

I had a new rack on my grande in the end..

Hopefully a cheaper..and simpler fix for you

Right, sorted my noise problem in the end, strut mounts and bearings were changed, and everything is fine now. But I can't say 100% for sure that it was those that were causing the actual clunk/rattle, I mean the bearings were quite seized, and suspension was turning in a jerky motion due to that, so they needed changing anyway, also the metal part with the hole on the mounts had a little play in that rubber, which means there could be metal on metal contact underneath, though it's hard to notice or check it after dismantling. It manifests only under the weight of the car and bumpy surfaces. It might give the impresion that it's still nice and pressed on the rubber if you are only trying to move it by hand.
Thing is I also found a broken spring, which means my pal Clunk could very well be the broken piece of spring which was sitting nice and loose on the lower spring seat. So if you have similar noises, it is worth to check up on that before going for the next step. At least in my case, I needed new mounts and bearings anyway, also new springs, and what a difference now. Let's see how long they'll last with nowadays spare parts...

Did my daughters top mounts the other day.

About 18 months ago i did the struts (Boge Sachs), lower arms etc. but couldn't detect any issues with the top mounts at that time. However, it came home from Uni just before xmas with a front end knock over uneven ground / speed humps.

This time on dismantling, both top mounts were dry and ended up with ball bearings all over the work shop floor.

2 new bearings installed and normal service is resumed but what is really, noticeably different, is the lightness of the steering!! Even my daughter commented on it!

In addition to failed strut mounts, I found the coil springs shift in their perch on the strut assembly, and can make noise. I think this is normal, and some lubrication will cut down on the noise considerably! Shoot some silicon or lithium grease into the cup at the bottom of each front coil spring, and enjoy a quiet(er) suspension!

I've never known coil springs to move when the weight of the car is on them.

vexorg said:

I've never known coil springs to move when the weight of the car is on them.

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We have a noise very like this, it was silent when I replace all the front suspension, after a few years the noise appeared even after a new spring(snapped after only a few years) the same noise is there only when the strut is compressed over speed humps, I can't work it out, it could be the strut but then both would have failed in the same way(same noise each side but more passenger)

Its just passed its MOT 12 years old 95k and NO advisories!

I think this is the same issue I have, not recently passed no advisories, but this noise particularly on rough road and speed humps.
Noise is front left side and just below window above wheel arch. I’m going to follow the guide to derust the top mount nut then have a look.

Here is the video to the noise I get when rocking the car by pushing on the roof

https://www.youtube.com/watch?v=CqIlkCPaZEk

Derbyfella said:

I think this is the same issue I have, not recently passed no advisories, but this noise particularly on rough road and speed humps.
Noise is front left side and just below window above wheel arch. I’m going to follow the guide to derust the top mount nut then have a look.

Here is the video to the noise I get when rocking the car by pushing on the roof

https://www.youtube.com/watch?v=CqIlkCPaZEk

Click to expand...

Broken spring possibly.

Ralf