I think I found a way to get rid of the clunk permanently...

[louis]

The problem with the rear sway bar bushings is that the I.D. (inside diameter) is the axact same size as the bar O.D. On other cars, the bushing I.D. will be a little smaller than the bar O.D. Now with time and mostly bumps the rubber gets squeezed and becomes loose on the bar, and that's when the clunk begins. I just unscrewed the sway bushing bracket and put a small piece of plastic (1 1/4" x 1 1/4", 1/16" thick) between the crossmember and the bushing. greased up the bushing with synthetic grease while I was there and put everything back together.
Let you know if it ever comes back, but I don't think it will.
(thumb)

 

[MrMp3]

Cool G. keep us informed

 

[Kooldino]

Nice, what kind of plastic did you use? What from?

 

[louis]

What it's from is not important. You can use a piece of metal or aluminum if you want. What's important is the thickness. I used plastic because it easy to cut and will not rust. Hell, I did'nt even replace the bushings when I did this and they have 24000km of wear on them! I'm pretty sure I'll never hear that anoying clunk again.

 

[MPChi]

Hey louis,

Thanks for the post. It would really save a lot of us MP3 owners if it does solve the clunk problem. I was wondering, could you post a couple pics if possible on where & how you placed the plastic and where to grease up the bushing? I am not very knowledgable on the suspensions, so some pics will definitely help.

Thanks again.

 

[louis]

There are 2 bolts holding each sway bar bushing brackets. On the picture you only see one on each side; the other bolt is just beside the ones you see. Just remove and put your spacer between the bushing and the cross member. It takes a bout 15 min and all you need is a 3/8 ratchet with a 14mm deep socket(you can't reach the front bolt with a short one).

 

[Allen]

I would love to do this if this will eliminate the squeaking/clunking noise to our MP3s in the cold. Sounds like an easy job that even I can manage. Keep us updated as to how it turns out, thanks.

 

[Kooldino]

There are 2 bolts holding each sway bar bushing brackets. On the picture you only see one on each side; the other bolt is just beside the ones you see. Just remove and put your spacer between the bushing and the cross member. It takes a bout 15 min and all you need is a 3/8 ratchet with a 14mm deep socket(you can't reach the front bolt with a short one).

erm...i dunno my suspension parts super well, can you edit the pics and draw arrows with #s next to them pointing to what you're talking about?

 

[Newf]

I tried this with mine months ago. Actually, Mazda of Canada suggested it to my dealer. I don' t know if they just did it wrong, used the wrong plastic or what, but it was REALLY bad afterwards once it started clunking again. It would actually creak as I sat in the car. We took it off. It'll scratch of the bar as well if done wrong. We tried the plastic trick 3 times...nothing.

Funny this should come up. My dealership called me some time ago, and said the head Canadian district reps and managers are coming in to check on the dealership on the 14th....they do this from time to time with everyone. Anyhow, he wanted my car there so he could show them. So, I left her there all day, and the manager of my dealership took them all out in her, and they all heard the noise. Of course, the squeaky shocks never made a noise ( it was raining, they don't ever seem to make noise when wet ) but the clunk apparantly....clunked quite bad. They were not impressed with it. For now, they are going to get me yet another sway bar, powder coat the ends where the bushings actually latch onto the bar ( this is to make it thicker so the bushings fit tighter), and of course I'm getting new links, new bushings, and new strut mounts AGAIN. Appararantly, they admitted that there has been quite a few problems with the strut mounts on ALL protege's. interesting.

Also found something else out. Mazda of Canada expects the dealers to pay for all of this. Well, not this time for myself, but up to this point, my dealer has been paying for over %50 of the cost of re-doing my bushings. I had to ask, as they have been fantastic about trying to help me, and I don't think it's their responsibility to pay for this stuff.

Anyhow, this whole process is going to take weeks, and with xmas coming, I'm sure shipping will be f'd up. The MSP will probably be here by then. I'll update again later on.

Good luck guys.

 

[Newf]

oh, and if your brave enough, just taking the bushings off, cleaning them up, and putting them back on tightly will cure the clunk for a few weeks. Lube them with something too.

 

[louis]

It'll scratch of the bar as well if done wrong. We tried the plastic trick 3 times...nothing.

...powder coat the ends where the bushings actually latch onto the bar ( this is to make it thicker so the bushings fit tighter),..

See what they did wrong is make the bushing smaller from the inside( where there is movement) So with time the tape or powder coat will wear off and the clunk will come back.
Now what I did was to make a pressure on the outside of the bushing so it will fit snug on the bar. No movement, no wear!
As for the squeek when it is cold, only regular lubrification will keep that away. The problem is that the inside of the bushing is of rubber. Rubber + metal + movement = squeek. the bushing should have a material that looks a little like velvet (like normal car companies) wich would prevent squeeking when cold.

 

[Newf]

hmmmm, interesting. Let us know how it works out.

 

[louis]

Well I've now reached 36,000 km and the clunking has not come back yet! I'm telling you the problem on my MP3 is fixed for good.
And remember, I did this modification with the old bushings, not new ones. So all of you looking for urethane bushings should try this simple trick first.
It worked for me...

 

[Newf]

so you went from 24 to 36 k?


interesting

 

[INiTiAL33]

isnt this the same idea as the teflon tape idea then?

 

[Newf]

post pics or something, I can't really see what it is that your saying.....remember, I'm with stupid


maybe make a CLunk fix for Dummies or something

 

[louis]

isnt this the same idea as the teflon tape idea then?

Almost but not quite.
See the tape around the bar will eventually wear ,tear or fall off because of the constant movement of the bar. What I'm doing is putting a pressure on the bushing from the outside so it fits snug on the bar.

 

[Newf]

ohhhhhhhhhhhhhhhhhhhhhhh, I get it now.....duh

Hmmm, maybe it would work.

 

[INiTiAL33]

O.... i get it now too..... Hmmm seems like its working for you....


Can someone actually type up something so i can bring it to my dealership and see if they can follow hte steps and help me do it?

 

[louis]

Did anybody actually tried this since I wrote about it.
'cause I'm now at 45000 km and no clunk to be heard yet.
I still get the squeek when it's cold, but since it summer for now...