Something is knocking after I replaced my strut assembly

[Kellsonm]

Hello everyone, I spent my day today replacing the driver's side strut, spring, strut mount/boot/bearing, sway bar link, and brake rotor on my '01 QX4 4WD.

I have also recently replaced my lower ball joints and tie rod ends.

After I finished the job today, I took it for a test drive and immediately noticed an alarming knocking sound whenever I go over the slightest bump, worse than before I replaced everything.

What did I do wrong? I followed the installation instructions as best as I could but I had some trouble assembling the strut mount.
1. I couldn't remove the old bump stop, so I left it on and did not replace it.

2. I noticed after I put everything back together that I forgot to put on this metal cylinder "sleeve" that I guess is supposed to go over the strut rod. There were no explicit intructions on how to install this so maybe it isn't that important…?

What could be causing the knocking? Nothing is loose enough to be shaken by hand, I tightened everything down with a good impact wrench.

Thanks for any advice!

[AZhitman]

Dumb question, but the last time I did that, I forgot to tighten my lug nuts.

Look closely at the metal sleeve - is it completely empty, or does it have a bumpstop built into it? It simply slides over the strut shaft.

Did you replace the strut mounts? They should be replaced every time you replace your front struts.

Lastly, I'm going to start looking at the sway bar endlinks.

Similar thread, may be helpful: clunk-from-front-struts-going-over-bumps-t565816.html

[rgk]

Personally I had a pretty bad knock until I replaced both end links and also the sway bar bushings.

[Kellsonm]

I put in a brand new sway bar link and it won't budge now so I don't think that's it.

I'll post a picture of the sleeve I left out.

My guess is that I assembled the mount incorrectly. I bought the KYB mount/boot/bellow kit from rockauto, can anybody further clarify the proper installation of these pieces?

[Kellsonm]

Here's that sleeve I didn't install.

[Kellsonm]

Here's the full exploded assembly:
The green check mark means I replaced with a new part, the blue "Re" means I reused the original.

[Kellsonm]

Some pictures:

[atraudes]

I had a slight knock/clunk after doing mine like something was flopping around and it ended up being the sway bar link nuts not being tight enough (they were already stupid tight and not loose at all). I torqued them down as much as possible and the knock went away.

If the knocking is loud it could mean your shocks are topping out. That spacer you're holding pushes the strut rod down a bit. I don't know how necessary it is, but if it is indeed topping out, my first step would be to get it installed. I used the ones included with mine because the nut was coming really far out of the top of the mount. I'm guessing the shocks are made to fit a different vehicle which requires a longer thread on the strut rod and since ours don't, they give us the spacer.

[Kellsonm]

Thanks for all the help. I will remove and disassemble the assembly on Friday, and I'll see if the spacer helps.
I also think I have the top seat turned 180 degrees, because there's a notch that's supposed to be facing inward, not outward, accepting to the FSM.

[Kellsonm]

*according to the FSM.

[AZhitman]

THAT would do it too - Don't drive it, it's binding. The arrow and orientation are important (even though it looks like it would function the same both ways).

Also, on the end links, if you can safely grasp one and hold it, while someone else bounces the opposite (and same) corner of the car, you may feel a clunk (inside the ball joint for the end link). Also, they LOOK to be tightened enough, but remember, you have to put an open-end wrench on the back-side of it to tighten the nut (I'm sure you did, but most people don't).

But I think you've found your issue. Grrr... I hate having to take apart a job I just did.

[Kellsonm]

I drove about 20 miles in it yesterday, but I took the time this morning to reassemble the strut assembly. I rotated the top seat correctly and made sure to install the spacer.
The clunking is better but still noticeable. Any things I can check? Everything in there is new!
I'll have my mechanic look at it too, this weekend.

[AZhitman]

Wonder if this is the infamous Pathfinder rear knocking... I can't recall offhand what causes it but if you search "pathfinder knocking suspension" you should find a few threads on the topic.

You're a pro with that suspension now!

[abnrjd]

That is a spacer that goes over the shaft. It takes up the slack when you secure the strut mounts. Make sure you tighten them to the specified torque also.