Sway Bar Noises - Saturn ION RedLine Forums
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post #1 of 18 (permalink) Old 10-15-2010, 09:36 PM Thread Starter
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Sway Bar Noises

my 2005 Ion RL's front end suspension makes clunking noises when going over bumps. I'm pretty sure it's front the sway bar system, not the struts. The struts don't leak and when I got it aligned, the mechanic said the struts looked okay.

Does anybody have a list of part numbers I should purchase? Should I go to polyurethane bushings? If I go with polyurethane, where should I buy them? Should I replace the end links? Should I replace anything else while I'm at it?

2005 Saturn Ion Redline, RevHard Dynotune, 2.8" pulley, 60# Flowmatched Injectors, NGK 1 Step Colder Plugs, Dual Pass Endplate Op-B, CXRacing Heat Exchanger, Mid Length Header & Downpipe, ZZP CTI 2.5 Over Axel pipe, Ingalls Stiffy Engine Dampener, OTT Rotated Trans Mount, GM Performance Clutch, V12 Motorsports Drilled/Slotted Front Rotors
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post #2 of 18 (permalink) Old 10-15-2010, 09:46 PM
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make sure your bushing mount is still held down, i've been told its a common problem for them to fall out, which minde did

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post #3 of 18 (permalink) Old 10-15-2010, 11:09 PM
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When mine clunked horribly it was the sway bar endlinks.


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post #4 of 18 (permalink) Old 10-15-2010, 11:36 PM
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I got the same problem but its from the bwoody sway bar. So becareful where you get aftermarket stuff from.
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post #5 of 18 (permalink) Old 10-16-2010, 09:16 AM Thread Starter
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I found a few part numbers

sway bar: 15782696
bushings: 15820164
Clamp: 22722387

Haven't found the endlinks yet though

2005 Saturn Ion Redline, RevHard Dynotune, 2.8" pulley, 60# Flowmatched Injectors, NGK 1 Step Colder Plugs, Dual Pass Endplate Op-B, CXRacing Heat Exchanger, Mid Length Header & Downpipe, ZZP CTI 2.5 Over Axel pipe, Ingalls Stiffy Engine Dampener, OTT Rotated Trans Mount, GM Performance Clutch, V12 Motorsports Drilled/Slotted Front Rotors
2000 Chevrolet Corvette Z51, 539rwhp
2008 BMW 335xi Coupe, 6-Speed

Last edited by tb30570; 10-16-2010 at 09:23 AM.
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post #6 of 18 (permalink) Old 10-16-2010, 09:31 AM Thread Starter
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I found more info for the Cobalt. I'm not sure if the Ion has the same front suspension as the Cobalt or not.

Condition #3
Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces.

Cause #3
This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture.

Correction #3
Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part.

Parts Information #3
Part Number
Description
Usage
Qty

20784686
Link Asm., Front Stabilizer Shaft (300 mm Shaft)
2006-2009 HHR (FE1, FE3)

2005-2009 Cobalt (FE1, FE3)

2005-2006 Pursuit (FE1, FE3)

2007-2009 G5 (FE1, FE3)

2003-2007 ION (FE1, FE2, FE3)
2

20784687
Link Asm., Front Stabilizer Shaft (250 mm Shaft w/Washer)
2008-2009 HHR (FE5)

2005-2009 Cobalt (FE5)

2007-2009 G5 (FE5)
2

20784688
Link Asm., Front Stabilizer Shaft (250 mm Shaft)
2006-2009 HHR (FE1, FE3)

2005-2009 Cobalt (FE5)

2005-2006 Pursuit (FE5)

2007-2009 G5 (FE5)
2

Warranty Information #3
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

E2147
Stabilizer Shaft Link Replacement (Both Sides)
Use Published Labor Operation Time

2005 Saturn Ion Redline, RevHard Dynotune, 2.8" pulley, 60# Flowmatched Injectors, NGK 1 Step Colder Plugs, Dual Pass Endplate Op-B, CXRacing Heat Exchanger, Mid Length Header & Downpipe, ZZP CTI 2.5 Over Axel pipe, Ingalls Stiffy Engine Dampener, OTT Rotated Trans Mount, GM Performance Clutch, V12 Motorsports Drilled/Slotted Front Rotors
2000 Chevrolet Corvette Z51, 539rwhp
2008 BMW 335xi Coupe, 6-Speed
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post #7 of 18 (permalink) Old 10-17-2010, 02:04 AM
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Hey I noticed you have the ingals torque dampener. When it gets cool out mine pops. Just something for u to think about.

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post #8 of 18 (permalink) Old 10-24-2010, 06:40 AM
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If you do need new end links powergrid makes a nice adjustable piece.

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post #9 of 18 (permalink) Old 10-24-2010, 09:13 AM
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Powergrid endlinks will get rid of the clunking.

If you drag race the car, and not autox/road course. Then you can just get rid of the front sway bar all together.
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post #10 of 18 (permalink) Old 11-08-2010, 11:49 AM Thread Starter
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more info from Cobalt

FE5 part numbers
Sway bar: 15821093
Clamps: 22608428('05 only , 1bolt/1slot) 10389617(2 bolt, ALL other FE5 including LNF)
Insulators: 22700091('05 only) 15822993(06-07 only)
Rear Axle: 15232752(same as FE3)
Links: 20784688(ALL FE5 same, including LNF)
Struts: 15247245/15247246(L/R)
Shocks: 22728821
Frt Springs: 21994335(L/R same)
Rr springs: 10390024(same as FE3)
Lower control arm: 15803766/15803767( L/R, right same as LNF)
Knuckle: 22667248/22667249(same as all except LNF)

2005 Saturn Ion Redline, RevHard Dynotune, 2.8" pulley, 60# Flowmatched Injectors, NGK 1 Step Colder Plugs, Dual Pass Endplate Op-B, CXRacing Heat Exchanger, Mid Length Header & Downpipe, ZZP CTI 2.5 Over Axel pipe, Ingalls Stiffy Engine Dampener, OTT Rotated Trans Mount, GM Performance Clutch, V12 Motorsports Drilled/Slotted Front Rotors
2000 Chevrolet Corvette Z51, 539rwhp
2008 BMW 335xi Coupe, 6-Speed
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