Hello,

Recently developed a rather harsh sounding creaking / popping noise from the front when making turns or going up/down inclines.

The only recent work that has been done was steering rack bushes and changing the shock top mounts to ones supplied by Steve.

Video here:
Any ideas would be much appreciated!

 

possibly the sway bar bushings or end links. Raise the front end, pop the wheel off and have a look around - post some pics

 

Sway bar bushing and end links were done about a year ago (2000 miles since then).

I did have a look at the lower shock to see how it has been fitted and looks crooked to me. ( didn't have the equipment to carry out the top mount change and dont trust myself around springs)
Does this look to be normal or cause for concern.

 

That is indeed cause for concern....

 

yikes - that's not right - definite cause for concern

 

The shop didn't line the lower mount up with the upper mount. You need to take it back to them.

 

Whie you are at it, have a look at the number of threads showing at the top nut on the mount.
Been having some issues with the newer washers not drilled properly and not going all the way to the shelf on the shock. You should be able to fingernail 5 threads between the top of the nut and the last thread above the nut.
Of course, like the rest, that lower bushing is not anywhere close. It must be in a neutral position between the lower A arm bracket. It's not rubber but more or less a U joint set in a plastic bushing, filled with grease, that's why the rubber seals on both sides.

 

To add to the comments of others and if the mount kit was one of mine the alignment instructions have been ignored by your fitter. Initially you could try removing the lower damper mounting bolt and sway bar link, let suspension droop and use a decent pry bar through the lower eye to realign. Should not normally be done with full spring force present but you may get lucky.

 

It was indeed on of your kits and I suspect they didnt read them properly.
I took it back to them today and they had said that the upper arm fulcrum bolt was seized on both sides and fixed that. Indeed the noise is gone and the car rides a lot nicer now, but when I mentioned the shock being skewed they brushed it off and mentioned that it can be normal...

so going to try and remedy this myself. Can I get spring compressors on whilst in situ, unbolt the top mount and loosen the top nut and twist the shock so it is aligned properly? Or would you recommend taking the entire thing off and realigning?

 

I am not aware of any spring compressors that will function with the shock assembly in situ....

You paid that shop to do a proper job for you. They did not. I would be hammering them until they get it right....

 

Not necessary but some caution is needed.
Get the car up and on stands, let the suspension drop. I would take some torque off the top three bolts inside the fender. Do not undo the central shock nut, a spring compressor on the spring is not needed.
Take the sway bar link off (top or bottom, which ever is best for you), will them let you drop the lower A arm down and give you access to let it drop and take the lower shock bolt out, you may have to jack the lower A arm up to get the bolt out. That after lowering the A arm will let you put in a large Phillips head screwdriver and give the lower part of the shock a twist. I generally put some WD40 on the bottom spring mount and a bit at the top where the spring sits on the metal plate below the packing donut.
After getting all bolts an suspension in a neutral position and ready for torque.

 

What did they do to "fix that"?. I wonder what state the upper control arm bushings are in...
Seriously, I'd get it re-checked. Sorry, anyone who mis-assembles something in that manner and then tries to fob it off as 'normal' shouldn't be turning spanners

 

Its an hour drive each way, its not an excuse but I just dont want to make the journey yet again.

Thank you for the tips Steve and Wayne, will give it a try likely Friday

The upper arms have been poly bushed so unless the sleeve had started to corrode onto the bolt? I'm not entirely sure.

I have been going to them for years, not with the XK mind, but with past cars. They did top mounts in the past for me which was fitted fine, the only issue being it was a URO part.
They have had a slew of new staff, so maybe its one of them...

 

Massive thanks to Steve and Wayne with this!
I ended up having to take the entre strut out and mount it upside down to get enough leverage to twist the shock back into position, but no broken bolts, no broken shock and the the bush still felt nice and tight so I guess thats a win!

All cantered in the lower arm now and ended up taking the fulcrum bolts out as well for peace of mind. Looks like they have started to corrode and pit so new ones may well be in the future, but that's about it.
Took it for a blast down some A roads and besides tracking being way out, handled beautifully