Clunking noise after complete front suspension overhall...(more)
 

I just went through and replaced my entire front suspension with the Febi Bilstein kit from PureMS. I also installed APR springs and Bilstein shocks at the same time.

I now have a clunking noise coming from the front passenger side that only happens when I'm off the throttle but I'm in gear. Its sort of a hollow thump/clunk that's rather rapid.

I double checked all the control arm bolts for tightness and I can't find any obvious issues. Any ideas on what this might be?

shock top nut?
 

did you re-torque all of the bolts with the suspension loaded?

No, I have not torqued things with the suspension loaded. Can I simulate that by jacking the...
 

knuckle up while the car is on jack stands or do I have to do while the car is on the ground somehow?

I wondered about the top nut on the shock as well, but I don't think thats it since the noise only happens on deceleration/coast while in gear. It's completely absent when coasting out of gear and while accelerating or maintaining a constant speed.

you can preload the suspension by jacking up on the knuckle.
 

Load the suspension up to where it would be sitting normally. Generally right around where the car lifts off the jack stands, and then down a bit (so it is stable on the jack stands again). Since it's on the ground already you can measure wheel center to fender and then reach the same measurement when you load it up on the jack.

Loosen the bolts a bit while the suspension is at rest, then load the suspension and torque everything to spec.

If anything- it will be better for the bushings... and it make fix your knocking.