pcy

BimmerFan52, after I saw your message, I went and removed the trim around the cabin filters, and checked the bolts on strut tower braces. They were tight. I was hoping the solution is something simple.

Tonyb635, thanks for talking to your friend. As I said above, I just checked the bolts on the strut tower braces. Then, I took mechanics stethoscope and I pointed the tip on each component while my wife turned the steering. The noise is amplified when I pointed the tip on tie-rod-ends. Since the outer-tie-rod-ends don't move at all, the noise must be coming from the inner-tie-rods or the rack itself :-(

BimmerFan52

While your wife was turning the wheel does it only one make one "clunk" per change in direction? Does the clunk come when the wheel is first being turned, at any time randomly during wheel rotation or at the end when arriving at the stop?

My experience with clunks is that something mechanical is slipping and suddenly stops (like the shock tower brace sliding under the fastener, even though the fastener seems tight because the hole in the brace is slightly larger than the fastener, or the end of a tie rod thread slightly stripped and slipping until stopped by a nut).

Gears can also clunk as they slip, unmesh and then fall back and remesh, and you may also want to check if you can isolate the main gear drive on the rack as the source.

If you haven't already, you may also want to throw the front end on jack stands and test both wheels unloaded to see if the noise is still there.

pcy

BimmerFan52, one clunk per change of direction.

I have a long reach 3 ton hydraulic jack. I will lift the front end tomorrow and see if the noise is still there with the front wheels unloaded.

pcy

I've raised the front end and tried the same, no noise while the steering is turned normally/slowly.
However, when I change the direction of steering really fast, then I hear the same clunk.

BimmerFan52

Having listened to the videos it doesn't seem like pressure builds up and then is suddenly release. More like some play in a fitting of some kind, as it seems like you have to jerk the wheel fast to make the sound.

If you have no adverse play in the steering during driving or issues with handling or ride and haven't seen any leaks, IMHO don't sweat it but just keep an eye on it.

travisbickle

I'd love to figure out what this noise is. PCY, doyou have the sport package with the active steering? My 2008 535i w/ sport package (active roll/active steering) has the same clunk but less severe. Which sort of makes sense since I only have 75,000 miles on mine. It's only noticeable while stopped or while driving over driveway aprons or speedbumps at an angle. I can tap the wheel with a rubber mallet and the knock isn't apparent and everything seems tight.

pcy

I spoke with a mechanic, who owns a specialty auto repair that rebuilds CV joints, regarding this clunk. I showed the videos. I asked him if loose rack mount bolts can cause that kind of clunk. He said that's a strong possibility. When I get a chance during the next couple of weeks, I will take the car to him and put the car on the hoist and look at the steering rack mount bolts.

twh

Have you checked out the steering u-joints? At least the upper one has a pinch point. I think it is accessible from under the dash. Once had a car with a loose pinch bolt and it made noises.

justoracle

I had a similar clunking noise, it was specially noticeable when trying to parallel park, this was the fix
https://5series.net/forums/e60-discu...3/#post1372719

About a year later, I noticed a different clunk specially when leaving from a parked position, it turned out to be the bolts for the front struts - the ones inside the engine bay. Tightened them up, clunking went away.

travisbickle

The noise is greatly reduced when the power steering is active and there is less torque on the steering joint assembly. This leads me to believe that the issue is somewhere in the steering joint assembly and not the rack. If there was play in the rack it would make the same amount of noise regardless of whether the power steering was working or not.