Hi all,

A year or 2 ago I replaced a stuffed front shock (damper) with a secondhand strut (damper + spring) from the wreckers for about $40. Did the job and got me back on the road, did the same when the other side went. Unfortunately as they were used I was lucky to get 12 mths out of them.

Decided to stop stuffing around and get 2 new KYB units for the olde girl. No probs installing the right side first as the left was still good and I had the next day to do that side. Anyway take her for a drive and I can hear a metal on metal knocking noise as I do sharp slow turns. WTF can it be. I check the old damper and realise that I haven't installed the lower rubber backing between the spring and damper. So I stuff around again and reinstall the spring to the damper with the rubber backing, take it for a test drive and all is fine.

So this morning load up the car for a Sunday drive and all is great till I pull into a servo too check the map. Do a couple of hard slow turns and theres that noise again. Not as bad as before or as easily induced but there nonetheless. I'm convinced its the lower spring base moving against the damper housing. I don't consider it to be dangerous but its disconcerting, especially for my wife as its her daily drive. I really don't know what else to do to stop the spring base moving relative to the damper housing. Any advice greatly appreciated.

The strut and strut top are out of alignment, that is whats making the clanking noise you here on turns.
There is a hole on the strut spring support, this llines up with a similar sized hole ot the strut top. Line these up(the strut complete will have to come out) then all will be fine.

So this morning load up the car for a Sunday drive and all is great till I pull into a servo too check the map. Do a couple of hard slow turns and theres that noise again. Not as bad as before or as easily induced but there nonetheless. I'm convinced its the lower spring base moving against the damper housing. I don't consider it to be dangerous but its disconcerting, especially for my wife as its her daily drive. I really don't know what else to do to stop the spring base moving relative to the damper housing. Any advice greatly appreciated.

I've had a problem like this with a new set of springs installed - in my case the top plate apparently wasn't put on in exactly the same position relative to the strut top as with the original spring, and so was rubbing against a rib formed where two panel sheets are welded together. As the problem got worse, the sound of the spring unbinding after a certain amount of movement was unmistakable. Reassembling the strut with more attention to the positioning of the top plate cleared the problem.

EDIT: grelise posted while I composed - better info in his post.