Suspension Popping/Clicking Noise

[Timothy1_17]

I posted what you see below on What did you do to your Kia Stinger today? but I figure I should start a new thread in the technical discussion area.

I hear this noise while driving slow, and when turning (anytime the suspension moves). It also makes a popping noise when putting it into gear, before even moving. And while raising and lowering the tire off the ground. It does not make the sound when parked and bouncing on the rear end.

First was wondering if it was a bad ball joint or control arm, some other suspension linkage? Then I shared some videos with my father-in-law, who guessed it might be a drive shaft joint or rear end. Then he sent me another text saying he's wondering if it's a half shift failing; like the joint is loading & snapping through its wear point. Not sure.

I will be contacting the dealer tomorrow to set up an appointment soon.

Here are a few videos.

https://imgur.com/uAwJbM6

https://imgur.com/Lj0h5nT

https://imgur.com/ssfqmjl

https://imgur.com/IaRHvaM

https://imgur.com/IkQfCtq

I reached out to my dealer, but I'm waiting on a call back from the service manager. Anything to help pinpoint of what it could be would be appreciated. Deviate brought up a possibility of the electronic parking brake might be fighting itself, or some other connection issue. Which could be something to look into since the dealer replaced the electronic parking brake on my driver's side shortly before I started hearing this popping noise. But would it make this noise just by jacking up and lowering the rear end when the car is off?

 

[Snicklefritz]

ima assuming that your other three wheels don't make any noises when raised and moved left and right? that driver's rear wheel making the noise like that would support the theory that the parking brake you had replaced is doing it. that'd be the very first thing to eliminate as a problem.

 

[D.J.]

Please share the results once fixed.

 

[Timothy1_17]

ima assuming that your other three wheels don't make any noises when raised and moved left and right? that driver's rear wheel making the noise like that would support the theory that the parking brake you had replaced is doing it. that'd be the very first thing to eliminate as a problem.

Correct, and that is what I am leaning towards right now.

Please share the results once fixed.

Will do.

 

[Timothy1_17]

A quick update...

Dropped the Stinger off at the dealership last night to have it worked on today. They called this morning blaming my Whiteline end links (of course). I argued with the advisor and the tech that it was making the exact same noise with stock end links, but of course they want to fight and have it put back to stock to look at it again and determine the issue.

They said they ruled out the electronic parking brake and that it is working fine. So, I then argued back and told them to look elsewhere if they weren't 100% sure it's from the end link. I suggested maybe the rear driveshaft or axel assembly, or some other rear suspension components. He agreed to take one more look and this time have the shop foreman check it out.

A couple hours pass and the advisor calls me back. They eliminated the end link (no kidding) and found it to be the upper control arm pillow ball busing. They said the only way that happens is when it's hyper extended — sounded like he wanted to point fingers and deny coverage, but he couldn't and seemed bitter about it. He then followed up by saying, we're not saying it was you who did this, but we're gonna take care of you and fix it under warranty.

How does one hyper extend the upper control arm on these cars? This is my daily, I have never taken it to a track or drag strip, never been in an accident, or have driven over curbs. Yes I have fun punching it and going around corners, but nothing crazy.

The hoops they make you jump through drives me bonkers. If they see a sticker on your car they try to weasel their way out of warranty work.

So, I'm pickering her back up today and will reschedule the work once the parts come in.

 

[Snicklefritz]

so, when you have the lr wheel off the ground, and you turn the wheel forward and backward, and it makes that clicking noise, that is somehow moving parts in your upper suspension?? wouldn't that mean that something or things are loose? I have no idea what 'hyper extended' means. stinger forum posts are good for learning new things.

 

[Timothy1_17]

so, when you have the lr wheel off the ground, and you turn the wheel forward and backward, and it makes that clicking noise, that is somehow moving parts in your upper suspension?? wouldn't that mean that something or things are loose? I have no idea what 'hyper extended' means. stinger forum posts are good for learning new things.

That is a good question and is above my knowledge as to if and how it affects it. But it's something I also thought of and is why I mentioned to them about the driveshaft / axel assembly.

I think what they mean by "hyperextend" is somehow the upper control arm was forcibly pushed beyond it's normal movement. Again, not sure how that could've happened, but there was never a big failure that happened while driving...just started hearing that popping noise about a month ago.

 

[Timothy1_17]

Final update on this one.

I had a family vacation for about a week and a half so I left my Stinger with the dealer to replace the upper control arm and pillow ball bushing. While I was out of the state, they gave me a few updates along the way on what they did and what didn't work.

They first replaced the control arm and busing...but still was making the noise. Then they thought it was the drive axle, so the foreman ordered new parts then replaced it with new. He said the noise was still there, and was going to try one more thing. I get a call a few hours later saying it's all fixed, ready to pick up and the noise is gone. I asked what it was and the advisor said it was the axle, but the tech forgot to torque everything down all the way and that's why it was still making a noise originally. Lovely.

All was under warranty, didn't pay a dime, so that part was good. Just picked her up yesterday and is back to driving like new with no more popping noise. Hopefully she stays outta the shop for a while.

 

[Snicklefritz]

why is it that the very first thing that should be checked is the last thing? in electronics it is something loose, in suspensions it is something loose! clearly any rattling popping crackling buzzing noises from ceiling doors dash or hatch are caused 99 out of 100 times by something loose....................

 

[D.J.]

advisor said it was the axle, but the tech forgot to torque everything down all the way and that's why it was still making a noise originally. Lovely.

Oh, that's no big deal!!

It's not like you and your family's safety doesn't rely on correctly torqued fasteners.

You don't "torque down all the way"
You torque to spec.

This dealership does not inspire confidence.

 

[Timothy1_17]

why is it that the very first thing that should be checked is the last thing? in electronics it is something loose, in suspensions it is something loose! clearly any rattling popping crackling buzzing noises from ceiling doors dash or hatch are caused 99 out of 100 times by something loose....................

Oh, that's no big deal!!

It's not like you and your family's safety doesn't rely on correctly torqued fasteners.

You don't "torque down all the way"
You torque to spec.

This dealership does not inspire confidence.

Right?! I couldn't agree with you both more.

One of the suggestions I asked form them to check (when I first dropped it off) was the drive shaft and axle assembly. Seemed like they dragged their feet to keep searching. Their egos were probably hurt when they wanted to blame my Whiteline end links and I demanded them to look further.

I was a bit dumbfounded when he said they didn't torque all the way down to spec at first. Yep, not like it was an accessory piece they were tightening down, it was the frickin axle! I'm just glad I've been babying my Stinger the past month or so, driving slow around corners & not punching the gas pedal, just in case it was suspension or drive axle parts.

Nope, not a lot of confidence from this dealer at all. I almost always have a fight with them when I take it in for warranty work. I always do a walk around (usually with my camera) when I drop it off and pick it up. Then I double check under the hood and under the car when I get home.

The majority of their staff do not seem to be car people/enthusiast and probably wonder why KIA even made the Stinger. The few people that are cool are too low on the totem pole to stand up against the higher-up advisors or managers.

 

[Timothy1_17]

Well, I heard the same popping noise yesterday and this morning. Not as loud and not nearly as often. Before it would make the noise every time I pulled in & out of a driveway or garage, made turns, went over uneven ground, etc...now it only happens once or twice per drive. Today I only heard once pulling out of my garage and once in the parking lot at work.

I'll look into this more and probably call the dealer today or tomorrow to have them do another once over. I'll post any updates.

 

[D.J.]

Well, I heard the same popping noise yesterday and this morning. Not as loud and not nearly as often. Before it would make the noise every time I pulled in & out of a driveway or garage, made turns, went over uneven ground, etc...now it only happens once or twice per drive. Today I only heard once pulling out of my garage and once in the parking lot at work.

I'll look into this more and probably call the dealer today or tomorrow to have them do another once over. I'll post any updates.

What was the bolt/nut/group of fasteners that they initially forgot to torque?

 

[Timothy1_17]

The advisor just said it was the rear driver side axle, he didn't give me a specific group, so I'm not sure if it's one of the arms. My mind was going there though, on if one or more nuts weren't torqued to spec. I will be calling soon to have them go back and check toques and/or figure out what is going on.