I just installed some Hotckis springs on my XB. They come with bump stops and I used those too. However, after taking a quick test drive, I drove over some slight imperfections in the road, and I am hearing a slight "clank" kind of like its metal to metal, but I am not positive and I think its on both sides. I have not had a chance to get back under the car to check it out, but I would like some suggestions as to what it may be so I can look for it.
I think i lined everything back up when re assembling the strut. Is it possible, if i didn't line everything up absolutely perfect that it would cause this noise? How about tightening down the big nut? I tightened it as much as i could with hand tools, but wasn't sure if that is enough.
Any help would be really appreciated.
thanks in advance.

**EDIT 4/21/05** I took apart the front suspension again last night. Trying to see if we did anything wrong from the original install. Unfortunately nothing is out of place. Everything is where it should be. HOWEVER, I think that I may know what the problem is. When reassembling the front struts, we have not been able to get a good enough hold on the strut to tighten down the BIG nut . So I think that when I hit something that is what is bangin' around in there. I also noticed when we took apart the strut the BIG nut was easily removed. SO now I need to know. How do I tighten down that BIG nut without rotating the strut shaft??? I don't have anything big enough to clamp it with and in the tutorial, they are just standing on it. (we tried this, and couldnt get it tight enough) So what has everyone been doing?

the springs are binding or..... the front upper strut mount is loose. with weigh on the car tighetn up the big nut it may be loose . is it a hollow type sound?

Is it coming from the front or the back? Can you push on the car by hand and make the noise?

It sounds like it is coming from the front. I have not tried to push down on it to see if I can make the sound, But I don't think it would happen that way. I nomally hear it if I drive over a manhole cover that is not perfectly flush with the ground. so i think its when the suspension compresses quickly.

As for the sound itself. it makes a sound like as if a trailer was dragging a chain on the freeway, and everytime the chain hits the ground, it makes that "tink" noise. I have already double checked the 3 nuts that hold the strut down, Those are tight, I have not had a chance to try the BIG nut, but i thought it was tight. I did not use an impact gun though. Not sure if that makes a difference.

If anyone can give me other suggestions, I would like to hear them so I look for it once I get a chance.

Is it possible that this is a normal sound for the break in of the springs? Like they are settling or something?

are their rubber sleeves on the coils themselves? that can cause metal to metal clanning, squeaking

The springs themselves are coated. maybe just powdercoated. It may be a cause. Not to sure though. But I did try pulling up and down on the side i hear it most from, and i thought i heard something. I will try it again when there is not as much noise around. But if I can hear it by me manually moving the car, what might that be?

is the sound comming from the bottom front of the car?

if so i too, have that same problem...

I would also check the subframe bolts. Many times those can be missed being tightened.

Every bolt on the underside is tightened down securely. So i don't think that is an issue.

I have edited my first post with a new possibility, and a question. By the way, my friend and I took apart the front end again, just in case, but same issue. Please read my edited portion of the fist post.
thanks for any help in advance.

Huh. Where abouts in the car do you hear this clank???

pop off the dust caps covering the big nut, and tighten while the struts are in the car, and the car is on the ground.

Randode, thanks for the input, I know you have done a lot of scions, so you expertise is appreciated. But i just want to make sure, that with the car on the ground, When I go to tighten the big nut down, the shaft of the strut is not supposed to move witht the nut. Correct? And with all the weight on the strut that should be enough pressure for me to tighten everything down securely..

Does the position of the strut cap make a difference once the strut is on the car? Because when I did the install the first time around, I lined everything up so it was out, as per stated in the DIY. When i dropped the car on the ground I tightened up the big nut as much as i could. So when I came back around the second time and took the strut off the car, the cap was not lined up like when I had originally installed it. So i figured that when I was tightening down the nut, it moved the strut cap. I hope that makes sense.

the strut shaft has 2 flat spots on it that must line up with the 2 flat spots one the spring hat. These are what stop the big nut from spinning the strut shaft. it sounds to me like the hat and strut are not alligned.

randode is correct...

During one of my spring installs this happened to me also.

The spring hat must be pushed down far enough so that the "flats" slide
over the flats machined on the sides of the strut shaft (below the threads).
The spring will be pushing up, making this easier said than done. A spring
compresser or a couple buddies make it easier.

Tighten the nut far enough on the threads so the spring hat won't lift up past
the flats.

Then reinstall the strut, finish tightening the top nut with the car on the ground.

Good luck...

or just put the weight on it and then while tightening the flat spots will "fall" into place and bam.

As stupid as it sounds, check the brake dust shield. I did a set of springs for a customer the other day and the dust shield was tweaked a little. So little bumps and hitting the brakes shifted the weight just enough to make the shield vibrate and hit the rotor. A little push on it and it was fixed...