Gents,

This is a pain, this issue.

We have an 02 XJ8 at the shop and my 2000 VDP SC. Both with CATS.

I bought a new set of N.O.S Bilsteins from WorldPAC with the orignial Jag part number. For the customers car, we bought the Bilsteins from Worldpac with the Bilstein part number instead of the Jag part number. They both reference each other, just looks like Bilstein is selling them direct now.

Both cars have developed a clack (not a clunk). For the customers car, we went ahead and replaced the entire suspension before hand anyways. This knock developed within about 3 months after the shocks were replaced. Upper mounts are fine.

I wasn't as lucky, I still have some old suspension, but I'm hearing the exact same noise after a trip up north. 4.5 months on the shocks. Absurd, really.

Has anyone received any defective Bilstein CATS shocks lately? This issue is going to be a big problem, unless we can throw shocks at them every 3 months (yeah, I know).

 

So, can this be the sound of 2 non-ferrous metals making contact? When is this sound prominent....always, cornering, bumps, acceleration, deceleration ....(when teenagers are in the back seat?...j/k, lol).
I would be suspect of a torn/failed bushing....for example, I replaced the front leaf on my Corvette along with new support bushings....when I attempted to apply torque to the bolts,..the bushings disintegrated.... they were over-baked in production.

 

This noise occurs on sharp sudden bumps. Those type that rattle you to the bone regardless of what you're driving. Think of an old asphalt road with the cracks and tears right before a pothole.

So, the plot thickens:

The XJ8 has poly's fitted to it. My car has the $100+ eurospare CATS upper shock mounts. Same exact noise coming from both. Metal to metal sounding.

 

It is worth a shot noting no one has thought of the lower bushings. Those sure would make a noise if they were DOA.

 

The lowers were my main thought, though I would want to consider all...though you state those are poly, but I have learned (because of the Vette) not to trust even new out of the bag items.

 

So funny you mention that - both cars original had those Meyle's - burnt out in a month. Well, let me be fair, my car lasted 2.