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Rear upper control arm issue

Bluemustang

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Some of you may have been following my suspension mods. I am switching to FR springs and shocks in hopes I will like the ride quality better.

Long story short, the work is done and the mechanic calls me- he says there's a squeaking creaking sound coming from the right rear. He narrowed it down to the passenger side rear upper control arm bushing. He showed it to me when they had the car on the lift. He unhooked the control arm- bounced the car- no noise. Rebolted it and low and behold - same creaking noise I heard before when I got my car back from Ford a few weeks ago after a basic alignment. Ford blamed it on my Koni shocks, saying it was a shock bushing.

The shop is ordering a new rear upper control arm with bushings for tomorrow.
Dunno why this is coming up now when it was fine before.

Just to recap- Rev auto installed all my parts in my signature. We went back and forth a few times to solve a clunking noise, also from the right rear. Eventually they fixed it. Drove it a month or so, no noises all good. I began to feel that my alignment was a bit off.

Took it to Ford dealer to basic alignment. Indeed the alignment was off. After I got the car back from Ford the creaking / squeaking noise began. Every time I hit a bump there it is. They claimed it was caused by a bushing in the shocks which is a different material than stock, and because the orientation of the bushing changed during alignment, it's going to make noise for a little while until it settles down. I said this is unacceptable b/c I had a car that was functioning OK and no noises and after they got it, bad creaking noises appeared. They wouldn't do anything for me and were basically like, "Oh I can replace the bushings but you don't want that." I don't trust them and won't take my car near them again.

Fast forward to today - found an honest local shop near me to put on the FR springs and shocks, which I thought would solve the problem. Although I didn't bring it in to solve a problem. I did it because I wanted different springs and shocks. Fixing the noise IMO was just a secondary benefit.

Is it possible this control arm has been the issue all along? Why would it have been fine after I got it from Rev auto and now it's not? I'm almost thinking that Ford messed something up during the alignment that has caused this. Obviously I can't prove that and I don't want the hassle. I just want my suspension good again and no noises. I just can't catch a break here guys. I wanted to improve my car and certainly didn't want to deal with this crap. I'm at my wits end here. After this is done, I don't want to hear about suspension any longer. It's become a bigger headache than it's worth. My family is making fun of me for this and acting like I'm crazy to want to upgrade my suspension. And I'm beginning to think they are right which is worse.

Any insight guys?
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BMR Tech

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I am not surprised to hear that this happened with the OEM Upper Link.

That mounting point on that upper link to the cradle, has a rubber bushing that features a design that is meant to "lock" the sleeve into place after it is torqued.

Between the design of the rubber bushing itself, and the fact that you can/will get noise from that sleeve to cradle contact area if there is any damage to the metal surfaces that affect clamping - you will get noises during suspension travel.

My guess is that, somewhere along the lines the upper link bushings were not indexed properly and that the bolts to the upper camber links were not torqued properly. Therefore, the bushing got damaged and the sleeve on the upper link is not working to hold the arm in place as it should. It could have even been from the beginning when you got your car new. I see bushings not clocked the proper way on stock cars, all the time.
 
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Bluemustang

Bluemustang

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I am not surprised to hear that this happened with the OEM Upper Link.

That mounting point on that upper link to the cradle, has a rubber bushing that features a design that is meant to "lock" the sleeve into place after it is torqued.

Between the design of the rubber bushing itself, and the fact that you can/will get noise from that sleeve to cradle contact area if there is any damage to the metal surfaces that affect clamping - you will get noises during suspension travel.

My guess is that, somewhere along the lines the upper link bushings were not indexed properly and that the bolts to the upper camber links were not torqued properly. Therefore, the bushing got damaged and the sleeve on the upper link is not working to hold the arm in place as it should. It could have even been from the beginning when you got your car new. I see bushings not clocked the proper way on stock cars, all the time.
So theoretically, a new upper control arm "should" fix it you think?
 

BMR Tech

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Yes. I do think it should.

When those protrusions on the OE sleeves get worn down, they do not grip the steel mount very well...and make annoying sounds when they slip just a bit.
 
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Bluemustang

Bluemustang

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Yes. I do think it should.

When those protrusions on the OE sleeves get worn down, they do not grip the steel mount very well...and make annoying sounds when they slip just a bit.
Once again thank you so much for your help and your input. Let's see if that does it. It's amazing to me how much you know about the S550 suspension.
 

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Bluemustang

Bluemustang

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Well the issue still persists. It is not quite as bad but still there. It's worse when I'm going slow and making turns.

Perhaps the driver side control arm needs to be replaced as well.
[MENTION=9985]BMR Tech[/MENTION] - any more insight on this creaking noise?
 
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Bluemustang

Bluemustang

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The creaking noise is definitely not as bad as before and now I think I hear it coming from the driver side.

The mechanic even said that if the passenger rear upper control had been bad, he was concerned that the driver side could develop an issue down the line. And if the noise persists the driver side control arm is likely the culprit.

I appreciated the honesty of the shop and the fact that they didn't want to give me back a noisy car. And replacing the right rear UCA the creak has lessened. Not hearing all down the road. Mostly driving slow over bumps or during a slower turn.

I'm thinking perhaps I give this one more try to alleviate this noise artifact and if unsuccessful then I just live with it and embrace it. After all I can't really hear it with my radio up and exhaust going.
 

Dominant1

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Your problem is that rev auto never installed it right in the 1st place, and just to think i was gonna get my suspension installed by them. You may remember me i was gonna have them do my n/a build, and they had my car for a month without touching it. So i'm glad i pulled my car outta there before they touched it. I Used a local guy here who is a mustang guy to do my suspension. I Gave him a picture of a diagram that shows which bushings to reclock & he was aware of it and did it. My suspension is quiet. When i showed that diagram to the guys at rev auto they gave me the look that said "oh shit more work". Adam is one of the best tuners but thats about all i can say about that place.
 
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Bluemustang

Bluemustang

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Your problem is that rev auto never installed it right in the 1st place, and just to think i was gonna get my suspension installed by them. You may remember me i was gonna have them do my n/a build, and they had my car for a month without touching it. So i'm glad i pulled my car outta there before they touched it. I Used a local guy here who is a mustang guy to do my suspension. I Gave him a picture of a diagram that shows which bushings to reclock & he was aware of it and did it. My suspension is quiet. When i showed that diagram to the guys at rev auto they gave me the look that said "oh shit more work". Adam is one of the best tuners but thats about all i can say about that place.
I would agree with you, I think you're right. But that it what it is, so now I think my best bet is to replace the driver side rear UCA and re-align. I may purchase some BMR camber bolts because the shop said my front end alignment was off OEM specs by .2 degrees. So I could get them to set the alignment exactly to spec while I am at it.

I do think the suspension was not clocked properly which damaged the control arm bushings. That would make sense based on what Kelly at BMR explained previously in this thread.
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