I've got a problem that I hope someone out there can help me with.

Recently I installed a set of Agency Power front adjustable swaybar endlinks to complement my newly acquired Progress Technology sway bars. Since then I've developed a knocking noise coming from the front end of the car. The knocking noise occurs when driving over bumps, cracks in the road, changes in grade, and generally any uneven surface.

I've inspected the links a couple of times to see if they'd worked loose, but everything is still tight. They only thing I've noticed is that the link is able to rotate back and forth a little bit. When rotating the link, the joint contacts the bushing between the joint and the mounting point on the lower control arm and causes a knocking noise. I think this might be the culprit, but I've found no way to fix it.

I was told by the company that I bought the links from (Fluid) that due to the design of the links that they are supposed to have some free movement and will sound different than the stock links. The noise to me is much louder and prevelent than I would consider to be acceptable though. It really sounds like something is broken or really loose.

There were no instructions provided with the links when I bought them, so I installed them according to the picture on AP's website. The nuts that secure the endlinks to the bar are tight, and the two nuts that tighten against the adjusting part of the link are also tight.

I'm really at a loss here. Anyone have any ideas or a similar experiece?

 

interesting. subscribed.

good luck. i have no idea, but i've been thinking about some AP sway bars and links.

 

tighten everything again, had that happen to me. turned out the nuts that hold the endlinks to the control arm got loose, even though they felt tight by hand

 

i had the same issue with another set of adjustable links..

check all the bolts on the links. and make sure you use a hex key while securing them.

beers

 

I actually have the racing beat sways and endlinks (installed for over 2.5 years).

I recently noticed this problem also... theres a knocking noise coming from the passenger front suspension once in a while. It felt like something was loose because I also felt a very slight click on my steering wheel when I hear the noise.

I took my wheel off to inspect the problem and everything seemed tight. In my mind I thought I might as well give the shock/strut (stock suspension) a check, and what do you know... the passenger suspension shock/strut was oily and greasy. So I have concluded that the strut is blown!

I dont know if this has anything to do with your problem, but I thought might as well point this out since I experienced the same knocking noise symptom. So I suggest giving your shock/strut a check.

hope this helps

 

AP Endlinks have some design issues that may wear them out too fast.

The distance to the uniball needs to be grinded of otherwise it will not work properly and eventually brake.

 

The endlink nuts need to be tightened to like 44 ft lbs. Get your torque wrench and some crows feet so you can get a hex key into the bolt and tighten that bitch down. Mine did the same and we're loose as hell.

 

I'm going to try some of the things you guys mentioned tomorrow morning. I also called AP a second time and they told me to take the links off and reinstall them with the car on the ground. I attached them to the bar originally when it was in the air, then adusted them after lowering the car to the ground. The guy I spoke to seemed to think that may have something to do with the issue. I really wish they would include some instructions with these things.

Thanks for all of the suggestions and I'll let you all know how it turns out.

 

I have the same problem with mine, it is cumming from the right side. After checking it out with my mechanic, when you push the front right side of the car down slightly it releases the pressure on the end link and clanks around. Nothing to do with tightening the bolts since I made sure they were tight numerous times. I am going to call Agency Power to see if this has been a problem for them as well, it sounds like there is a defect in the way it is made. I'm glad I,m not the only one with this problem.

 

Sorry it took so long for the follow up, but here it is:

After some thinking, I decided to adjust the links a different way to kill the knocking noise.

I ended up loosening both of the nuts that tighten against the adjusting part, then rotated the upper joint all the way to the right, then the lower joint all the way to the left. Once they were in place I tightened the nuts back down. This eliminated 99% of the rotation of the link which was causing the knocking noise when it rotated and hit the mounts. Shizaam! Knocking noise is gone!

One side is starting to make a little noise again. I suspect that I didn't tight down the adjusting nut enough. I'll tighten it again on another day.

Now, I'm not sure if this is the exact way to fix the problem, but it worked for me. My only concern is that it might not allow the link joints to articulate as much as they did before, possibly causing premature failure. In other words, I'm not responsible if this fix effs up your links. So far so good for me, but fix at your own risk.

BTW, I still think it's lame that AP doesn't include any kind of install/adjusting instructions with the links.....

 

I've had the same issue...very annoying. I've had to tighten them again, but I don't think that's the issue. Tightening while the car is flat or completely loaded makes sense. But that will take ramps or a lift. Maybe it's time to buy some ramps.

What other endlink options do we have? The stock ones failed (even the update ones per the TSB). I'd rather have a bit of play and not deal with very load clunking noise. It sounds like the entire front suspension is loose, which is not the case.

 

^^

am currently dealing with this situation.... just installed the front progress bar with custom spherical bearing adjustable endlink (similar to AP endlink) and after some driving it started developing light noise and gradually louder.

to cut the story short. the bolt size that mates up to the sway bar hole is too small. and i'm gonna work on a fix/solution once i get my rear progress tech sway bar in before installing.

this issue really drags as i've made everything similar to oem size on my custom endlinks and have really anticipated the sway bar hole being much bigger......

so to answer you shortly, you have to upgrade to a beefier endlink with a bigger bolt size. either that, or switch to a different bar with a smaller or oem sized adjustable hole.... and we both know which one is easier....

i guess that must be the reason why RB wants you to use their endlinks with their sway bars... it must be that they are properly sized to each other on both ends... though the only thing bad about it is that it isn't length adjustable or stiffness adjustable.

GL to u.

 

I have a custom set of AWR front endlinks with integral studs, never had any problem with them

I have seen people install them backwards, the endlink needs to mount on the rear side of the control arm mounting tab, not the front side ...

I ran the Progress bar with OE endlinks without issue, a larger stud of the RB links doesn't do anything but make you drill larger holes in the bar

 

The knocking noise is back....... How frustrating!

They're installed on the control arm mounting tab the proper way too.

I may just end up selling them and reinstalling new OE ones.

Major

 

The problem with most of those endlink assemblies is they use low quality heims. High quality heims will stay tight and last a long time, but they cost 3x - 4x more than the cheap ones.

The endlink stud or bolt being smaller than the hole in the bar arm shouldn't be the cause of knocking if it's tightened properly.

You need to make sure that the swaybar pivot bushing brackets (D-bushings) are centered on the hold-down studs before tightening them down to spec. Doing this properly means the top portion of the swaybar bushing bracket overlaps the the bolt head for the ABS cable hold-down. The bracket will bend down around it once it's tightened down. On another thread somebody had an issue with the pivot bushing bracket bending and causing a knock due to it not being centered - this created a long distance between the hold-down nut and the bushing that allowed the stiff bar to bend the bracket and make the bushing loose, which was the cause of the knocking.

https://www.rx8club.com/series-i-trouble-shooting-95/progress-anti-sway-bar-bump-noise-fix-176182/


.

 

I think I have found the issue. The metal used seems to be too soft.

Here a picture of the metal spacer before the installation.


And here is the same spacer after 5000 km.


As you can see the spacer has a groove after a while, probably from the friction and the pressure of the endlink himself. This grove makes the spacer loose after some time and could create that knock sound that we all ear.

So the solution could be to make a new spacer in a harder metal and while we are at it, why not make it conical so there would be no chances to hit the endlink.
Another solution would be to add some sort of polyurethane washer to reduce the friction.
I will try the second solution today and will make new spacers during the winter.

 

The knocking noise can be from a loose endlink nut. On my racing beat endlinks one end link nut would not hold and back up a 1/4 turn causing the knocking. Every since i replaced the nut no problems

 

You are probably right.

I just reinstalled the end links with a rubber washer + 44lbs of torque on each nuts. That way, there is no way the nuts will move.
So far the noise has totally disapeared, I'm not sure if it will last long. I will keep you posted.

 

You should also use some loc-tite for some extra insurance

 

Finally the annoying noise came back.

I guess that I will have to make a new set of spacers in stainless this winter.

 

I've still got the knocking and I'm done trying to fix it.

Anyone wanna buy some endlinks?

 

Some good reading and info for ya
AP Sway bar install. End links installed WRONG with pics and endlinks installed the right way with pics https://www.rx8club.com/series-i-wheels-tires-brakes-suspension-55/installing-ap-sway-bars-164567/page3/
and bent oem end links with after market springs https://www.rx8club.com/series-i-wheels-tires-brakes-suspension-55/attn-tanabe-spring-owners-165037/

 

Did you try calling Agency Power and tell them your problem. Maybe they will send you out new Endlinks or point you in the right direction to get it fixed. I was having problems with one of my Racing Beat Endlinks. The passenger side endlink nut would back off a 1/4 turn or so and cause a knocking sound. So i found new nuts and replaced them and even added some loctite. Problem never came back

 

I contacted Agency Power yesterday about this issue. I must admit that they answer their messages very quickly. I will see if they can find a solution. Hopefully they will think about their design and maybe make some changes. I am currently contemplating the Racing Beat end-link. But it's not adjustable and I will have to drill my sway bar and the control arm

I also have an update on my issue, which is probably the same for many of you. I finallly pinpointed where the sound was comming from.... lets see the video...

 

thread revival! (: did anyone find a good solution to this problem?? this noise is killing me. makes me think that something is going to break every time i hear it.