Noisy Boxster Rear Suspension

[w_pienaar]

Are there any known problems with the Boxster’s Rear Control Arms. My 97 Boxster has an awkward clank type rattle. This is evident when driving over bad road surfaces. The rattle noise can be heard clearly when driving over the reflectors located on the centre line road markings. I initially thought is was the wooden sub-floor beneath the carpet in the boot. I have removed every thing from the boot (carpet and wooden floor) but the noise persists. This then led me to believe that it must be a rear suspension noise.

I have been to an OPC and they could not identify the problem. I have been to my local Porsche Specialist and he recons it is the two Rear Control arms.

I have gone through a process of elimination. I have detached the roll bar drop links but the noise persists. I have also inspected the rear suspension top mounts whilst my wife was driving. Small movements could be felt, which is normal as far as I am concerned as the rubbers compress during normal suspension operation.

Before I resort to my next and last option to have the control arms replaced which will be an expensive exercise (+/- £250 each) I would like to know whether this a known problem on the Boxster (or other models) and if anybody had a similar problem in the past.

P.S. I have attached an image of the Rear Control Arms.

Cheers

[insite]

this is a known problem. the control arm ends each have a bearing in them; the bearing rides on nylon bushings. the grease runs dry, the nylon wears, and the bearing gets loose. you will notice the sound a LOT more when it's cold out. it IS possible to press out the race / bearing assembly, but i've yet to find a replacement unit. i'm also working on fitting zerk type fittings to these so that i can add grease and hopefully get rid of the clunk without buying new arms. i wish porsche made their suspension parts servicable.....

i know you're in the UK, but you may be able to get some replacements from a porsche boneyard near me. i bought one from German Auto Dissmantlers for about $100 US.

if i find another solution, i will post it.

Edited December 12, 2006 by insite

[insite]

i thought of something else. i have a spare (bent) one of these control arms that i've taken apart. i'm going to see if i can fit some shim stock between the nylon and the aluminum housing to close the gap. the nylon bushings have notches in them through which new grease could be injected. then, the boots could be re-installed and all will be well. i'll post pics if i get it to work.

[w_pienaar]

Thanks for your prompt reply. I am eagerly awaiting your findings and photos.

[FIG]

I too had the same prob. (noise over bumps from right rear)

I was lucky it was under warranty though, and my dealer replaced BOTH control arms.....DONE, fixed the prob.

Hope all goes well!

Cheers

[insite]

well, i've found that TRW makes the bearing cartridge. now i just have to source it... it should be possible to press out the old and press in the new.

[Boxxy]

I have the same symptom in my 2001 2.7. I was thinking the soft top mechanism was loose or something like that but what you guys have said (noise at the right rear) sounds just like my problem.

I'm hoping there is a simple solution. Thanks in advance for any tips and pics.

[Porsche_Joe]

My car is a 98 with 79,810 miles. I had the same clunking sound from my rear suspension. I replaced the trailing control arms today and the clunking sound is gone. I also installed new nuts and bolts. I could not move the bearing on the new arms but the old bearing could be moved easily with my fingers after it was removed from the car. It seemed fine when it was on the car. I don't see how you can check them without disconnecting the trailing arm from the lower control arm. Then you can move the arm and feel the movement at the bearing.

Edited December 24, 2006 by Porsche_Joe

[CJ_Boxster]

well, i've found that TRW makes the bearing cartridge. now i just have to source it... it should be possible to press out the old and press in the new.

Could you give us the part number and link to the bearing cartridge so that the info stays on the forum for good?

[w_pienaar]

Problem solved. I replace the 2 control arms. I am now a happy bunny. :clapping:

Thanks to all that gave some inputs

[Tony Roma]

Problem solved. I replace the 2 control arms. I am now a happy bunny. :clapping:

Thanks to all that gave some inputs

I have this same problem, what costs were involved, thanks

[Porsche_Joe]

Problem solved. I replace the 2 control arms. I am now a happy bunny. :clapping:

Thanks to all that gave some inputs

I have this same problem, what costs were involved, thanks

I paid $609.48 for the rear trailing control arms and $28.54 for the nuts and bolts, a total of $638.02. I installed them myself so there was no labor charge.

[Boxxy]

Any news on the replace-just-the-bearing front? I'm glad there is now a proven solution (replace the arms), but I'd rather not spend $600+. Out of curiosity, what could the new bearings cost?

[CJ_Boxster]

Any news on the replace-just-the-bearing front? I'm glad there is now a proven solution (replace the arms), but I'd rather not spend $600+. Out of curiosity, what could the new bearings cost?

insite above said he found a manufactor of the bearing cartridge but i asked that mofo to give us the part number and the company who supplies it but he hasnt replied in nearly a month.

Edited January 9, 2007 by CJ_Boxster

[insite]

Any news on the replace-just-the-bearing front? I'm glad there is now a proven solution (replace the arms), but I'd rather not spend $600+. Out of curiosity, what could the new bearings cost?

insite above said he found a manufactor of the bearing cartridge but i asked that mofo to give us the part number and the company who supplies it but he hasnt replied in nearly a month.

never found a source for the part. it's a TRW bearing, but no part numbers on it. i did some experimentation with modifying / repairing the cartridge with mixed results. it will be a lengthy post; i'll get it up this week (lots of pics).

[CJ_Boxster]

Any news on the replace-just-the-bearing front? I'm glad there is now a proven solution (replace the arms), but I'd rather not spend $600+. Out of curiosity, what could the new bearings cost?

insite above said he found a manufactor of the bearing cartridge but i asked that mofo to give us the part number and the company who supplies it but he hasnt replied in nearly a month.

never found a source for the part. it's a TRW bearing, but no part numbers on it. i did some experimentation with modifying / repairing the cartridge with mixed results. it will be a lengthy post; i'll get it up this week (lots of pics).

cant wait!, The idea of removing the cartridge from the arm and filling it with urethane and a sleeve ran through my head but, urethane would likely not be able to handle the shock and twisting that the rear control arm does.

[CJ_Boxster]

I just called TRW and they say they dont have any aftermarket listings for Porsche boxster, No bearing cartridge at all.

[alstarz88]

I just called TRW and they say they dont have any aftermarket listings for Porsche boxster, No bearing cartridge at all.

i replaced some bearings in the pulleys on my engine from a shop that specialise in just bearings if i had all the measurements or the bearing the self i should be able to get them i to have a knocking noise from the suspension i will look at mine and see if i can get the bearing.

i also have a random knock which i thought were the wire ties that hold down the roof. my noise comes from the left rear

98 boxster UK

[CJ_Boxster]

I just called TRW and they say they dont have any aftermarket listings for Porsche boxster, No bearing cartridge at all.

i replaced some bearings in the pulleys on my engine from a shop that specialise in just bearings if i had all the measurements or the bearing the self i should be able to get them i to have a knocking noise from the suspension i will look at mine and see if i can get the bearing.

i also have a random knock which i thought were the wire ties that hold down the roof. my noise comes from the left rear

98 boxster UK

Please do! It would mean alot to us all!!!! Usually the rear control arm rattle is worse on hotter days, and makes lost of noise at low speeds over cracks and bumps in the road... hopefully thats what your expierencing and the Shop you take your car to will locate the bearing for the application!!!!!!

[Tony Roma]

I just called TRW and they say they dont have any aftermarket listings for Porsche boxster, No bearing cartridge at all.

i replaced some bearings in the pulleys on my engine from a shop that specialise in just bearings if i had all the measurements or the bearing the self i should be able to get them i to have a knocking noise from the suspension i will look at mine and see if i can get the bearing.

i also have a random knock which i thought were the wire ties that hold down the roof. my noise comes from the left rear

98 boxster UK

The exact same place mine comes from, would be great to get it sorted, cheers

[insite]

I just called TRW and they say they dont have any aftermarket listings for Porsche boxster, No bearing cartridge at all.

i replaced some bearings in the pulleys on my engine from a shop that specialise in just bearings if i had all the measurements or the bearing the self i should be able to get them i to have a knocking noise from the suspension i will look at mine and see if i can get the bearing.

i also have a random knock which i thought were the wire ties that hold down the roof. my noise comes from the left rear

98 boxster UK

Please do! It would mean alot to us all!!!! Usually the rear control arm rattle is worse on hotter days, and makes lost of noise at low speeds over cracks and bumps in the road... hopefully thats what your expierencing and the Shop you take your car to will locate the bearing for the application!!!!!!

it's not a normal looking bearing; here's a pic of the cartridge:

[CJ_Boxster]

I just called TRW and they say they dont have any aftermarket listings for Porsche boxster, No bearing cartridge at all.

i replaced some bearings in the pulleys on my engine from a shop that specialise in just bearings if i had all the measurements or the bearing the self i should be able to get them i to have a knocking noise from the suspension i will look at mine and see if i can get the bearing.

i also have a random knock which i thought were the wire ties that hold down the roof. my noise comes from the left rear

98 boxster UK

Please do! It would mean alot to us all!!!! Usually the rear control arm rattle is worse on hotter days, and makes lost of noise at low speeds over cracks and bumps in the road... hopefully thats what your expierencing and the Shop you take your car to will locate the bearing for the application!!!!!!

it's not a normal looking bearing; here's a pic of the cartridge:

So is the rattling due to that white nylon jacket wearing thin around the ball?

[insite]

So is the rattling due to that white nylon jacket wearing thin around the ball?

it starts to allow the ball to move up and down in the sleeve.

[CJ_Boxster]

Ahh i see, Up and down, I would have thought side to side but up and down would make more noise... Hey, would you say that the Nylon is wearing or would it be a combination of the metal ball and the nylon?

If anyone here new anything about nylon molding or knows of someone that can make a remake of a new nylon sleeve using a new nylon sleeve as a template, we could all save hundreds of dollars!!!

[insite]

Ahh i see, Up and down, I would have thought side to side but up and down would make more noise... Hey, would you say that the Nylon is wearing or would it be a combination of the metal ball and the nylon?

If anyone here new anything about nylon molding or knows of someone that can make a remake of a new nylon sleeve using a new nylon sleeve as a template, we could all save hundreds of dollars!!!

actually, i don't think it wears. the nylon sleeve is held in place by a metal crimp (see pic). i think the crimp loosens over time and allows the entire nylon sleeve to slide within the control arm. my 'workaround' has centered on re-setting the cartridge and re-crimping the arm. so far, i've fixed one and made one worse. still working on a real solution.