Powerflex Thrust Arm rubbing issues

NousDefions · 29th September 2011, 02:24

So, a few months ago I installed both lower and upper control arm Powerflex bushings and have been pretty happy with them, except for one huge issue. The thrust arm bushing is rubbing the sway bar mount, specifically the washer for the bushing. It's pretty much in constant contact and during hard stopping and turning it makes a nasty noise, like a big clunk.

I haven't heard of anybody else having this problem. What am I doing wrong? I posted some pictures for reference so you can see the contact I'm talking about.

TMcNasty · 29th September 2011, 03:07

I'd love to help you, but I was unable to get both metal washers in place. I'm not 100% sure, but I'd bet that's the side I left mine off of hence no rubbing. You could probably (pretty safely) grind down some of the washer and outer rubber edge there to make a little gap. I only have one washer per side so you'd still be way ahead of me. 20k miles on these without issues too.

NousDefions · 29th September 2011, 03:52

I think that's what I'll do. Grind down all the way around at an angle, perhaps a 1/2" of material. It's just strange that nobody else seems to have the same issues, and I installed it properly. My mechanic bad-mouthed the product when he saw them (I had him do the rear ball joints, because it was cheaper to pay him than buy the darned tool).

gixxeridaz · 29th September 2011, 03:57

no issues with myn?

NousDefions · 4th October 2011, 02:32

Update:

I got the local machine shop to take the washers down by about 3/8's of an inch, and bevel the swaybar side of the bushing to meet the washer.

Success! No more clunking under braking or turning. Rides a lot smoother than before, too. Not sure why they don't just make them this way in the first place.

TMcNasty · 4th October 2011, 06:35

Im not 100% sure but I think these fit perfectly in a non-M E39. Thinner swaybar? But I agree...they should tweak it for the M so we don't have to tinker with them.

NousDefions · 4th October 2011, 07:02

Quote:

Originally Posted by TMcNasty

Im not 100% sure but I think these fit perfectly in a non-M E39. Thinner swaybar? But I agree...they should tweak it for the M so we don't have to tinker with them.

I don't know if the welded on swaybar mount is thicker in the M cars or not.

Unlike some others here (including you), I have no issues getting the washers in. I'm very happy they work now, though. The car drives the way it was supposed to. I was going to be angry if I had to go back to OEM bushings because I couldn't get the Powerflex to work.