I started to notice the infamous clunk (those who have PSS9) from the front of the car last year. It was only noticeable at slow speeds <2-3 mph. I took the car to dealer to inspect the end links and they said those are tight as hell. The car was under warranty, so it would have been considered a warranty item, but they didn't see anything wrong with them.
The noise radiated through the steering and it felt like something is broken in the front. So I lived with the noise but up to a month ago I coulndn't take it. I researched forums and came up to a thread that mentioend the same symptoms as me.

To make the story short, found out on the new PSS9 kits, they come with new washers that eliminate the clunking. These washers were not available on the PSS9's that were bought few years back, but Bielstin has a kit that eliminates the noise for those. The kit is free from Bielstin but the labor is not covered. Lucent had a kit in stock and installed it for me. The noise is gone.
While they had the coilovers out, they also cleaned the dust/grease/sand from the top of the coilover, washed the brackets with circuit cleaner, re-applied grease and installed the new kit for me. I paid around 2-3 hours of labor, but it was well worth it.
Good luck.

 

interesting.

would be willing to do this myself. Think I can just call them and ask for the kit? any part numbers or pics from the install?

 

My M3 currently has this problem. It's common to coilovers. Since there is no grease gasket or anything up on top of them, the grease wears off over time and it can produce this clunking sound at low speeds. Handling is not effected, but the noise is annoying. You should just be able to slather some grease up there and it'll go away

edit: im not on pss9's. It's great if theres a more permanent solution, but above is what I was told to do for any coilover in general.

 

I'm interested in this too if you can just call them up and get the "kit" to DIY?

 

I don't have all the tools to do a job like this, but when I watched, it wasn't too bad. Bilstien does give the kit for free, however, you gotta call them up. I will find the number and post here.

 

I heard these folks also sell their own kit.
http://www.swiftsprings.com/products..._products.html
But from Bilstien is free of charge.

 

I too am interested in this free kit from Bilstein - any part number would be appreciated and a point of contact at Bilstein

thanks for posting this

 

I have contacted Bilstein East Coast, where I've had great results talking to their "PSS9/10" guy. He's never heard of any such kit or new washers. But he's going to contact the California location and find out what this is all about. I'll keep you posted on what I find.

 

OK, I got the answer. Well, maybe not THE answer, but AN answer. Bilstein in NC and CA have no idea about any free kit to fix the clunk. If the OP has any info, that would be great. HOWEVER, the equivalent solution is pretty cheap. If you looked at your original PSS9/10, the bottom, helper spring, rides on top of a large blue plastic washer, between the spring and the adjustable spring perch. You can order another one for the top of the front helper spring, (2 total needed) 60mm, part number E4-XK6-Z002A00 for $1.50 each. You can also order 70mm ones for the top main springs, front & rear, and the rear helper springs, part number E4-XK6-Z002A01, 10 required, same price. However, the lip on the top spring cup, under the RSM, is pretty shallow, and reducing it by 1.5mm might not be too good an idea. Also, how much clunking comes form the rear, anyway? If you install them, order 2 new main top nuts, as the nylon lock ones are one use only. All the parts form Bilstein, 12 washers and 2 nuts, was $25 shipped. Naturally. as the washers are 1.5mm thick, if you add 3 new ones, then the car is raised 4.5mm higher than the designed range, and that must be accounted for in keeping it within Bilsteins lowering limits. Bilstein east coast is 1-800-745-4636, ask for Parts or Kieth Robertson. They ship out of CA, so you might also want to call CA direct.

Hope others with PSS9/10s find this helpful.

 

Thanks for this info - did you install the parts and was the horrendous clunking fully remedied?

 

Part numbers for '99 C4, according to Clarence in Bilstein's CA office (1-800-537-1085):

Front helper spring (60mm) = 2 x #E4-XK6-Z002A00
Top main springs (70mm) = 10 x #E4-XK6-Z002A01
Front locking nylon nuts (M14x1.5)= 2 x #2517670

Total is $15.70 before shipping. Hope this will end the clunking!

 

Be sure to post your results after installation!

 

Turns out I had two probs: The rubber on the upper strut mounts had become brittle and dry (I sometimes forget this is an 11 year old car) they were not providing any dampening effect. Replaced those and installed the blue Bilstein washers. Loving the car now. All dialed-in and all tight, no clunking and handling much improved. Anyone else experiencing clunking from front on an early 996, check your mounts!

 

Great Post! I realy hate that clunk. Anyone have details for DIY?

Thanks

 

i have the same thing... typically onset is when i go up a curb at slow speed... but i have ING not PSS9