Aaargh! Chassis bracket for RSB busted off!
#1
Racer
Thread Starter
Aaargh! Chassis bracket for RSB busted off!
How screwed am I?
I have had a Comptech rear sway bar for about 3 years now with no problems other than having to regrease the bushings.
A few days ago I started hearing a clunking sound from the rear of the car. At first, I just thought that there was something banging around in the trunk -- nope, all clear.
Then I read a thread about loose end links creating noise, so I jacked up the car to tighten the end links when I noticed that the right bushing bracket looked not quite right. The sway bar bracket and the bushing looked fine, but the chassis bracket (that you mount the bushing bracket to) has broken off of the chassis! So the sound that I've been hearing has been the sway bar bouncing up and down and hitting the chassis.
Does anybody have any idea how much this is going to cost to fix? Can they re-weld the original bracket back to the chassis? Should I take this to the dealer or to a suspension shop?
I have had a Comptech rear sway bar for about 3 years now with no problems other than having to regrease the bushings.
A few days ago I started hearing a clunking sound from the rear of the car. At first, I just thought that there was something banging around in the trunk -- nope, all clear.
Then I read a thread about loose end links creating noise, so I jacked up the car to tighten the end links when I noticed that the right bushing bracket looked not quite right. The sway bar bracket and the bushing looked fine, but the chassis bracket (that you mount the bushing bracket to) has broken off of the chassis! So the sound that I've been hearing has been the sway bar bouncing up and down and hitting the chassis.
![ugh](https://acurazine.com/forums/images/smilies/ugh.gif)
Does anybody have any idea how much this is going to cost to fix? Can they re-weld the original bracket back to the chassis? Should I take this to the dealer or to a suspension shop?
#2
Pro
Thread here about this http://www.acura-tsx.com/forums/showthread.php?t=36339
#5
Racer
Thread Starter
Just to be clear, it wasn't the end link that broke; it was the mounting bracket for the RSB clamps.
While this may be one of a few cases reported thus far, I wouldn't be surprised to see many more in the future. I've been running with this setup for about 3 years, so I think it's the cumulative stress that finally broke it. For others who have had their sway bars for a shorter time period, I'd be concerned.
I am going to take it to the dealer tomorrow just to see what they say. I have no expectation that they'll fix it under warranty, but I'm hoping that they have a certified welder on staff or can recommend one. I will ask the welder to beef up both sides and then I'll need to think long and hard about re-installing the Comptech or going back to stock.
While this may be one of a few cases reported thus far, I wouldn't be surprised to see many more in the future. I've been running with this setup for about 3 years, so I think it's the cumulative stress that finally broke it. For others who have had their sway bars for a shorter time period, I'd be concerned.
I am going to take it to the dealer tomorrow just to see what they say. I have no expectation that they'll fix it under warranty, but I'm hoping that they have a certified welder on staff or can recommend one. I will ask the welder to beef up both sides and then I'll need to think long and hard about re-installing the Comptech or going back to stock.
#7
Racer
Thread Starter
Originally Posted by afici0nad0
do you use the included bushings from comptech, or did you replace those with some polyurathane ones?
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#8
Three Wheelin'
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IS your TSX an 04 or an 05? I think the other one that clifton had was an 04 and if i remember correctly, the rear had some more support on my 06 then it did in my 04 but i could just be making that up....lol.
#9
Pro
Originally Posted by jwood_06TSX
IS your TSX an 04 or an 05? I think the other one that clifton had was an 04 and if i remember correctly, the rear had some more support on my 06 then it did in my 04 but i could just be making that up....lol.
If I had to guess, I'd think the hard urethane bushings are as responsible for the failure as the stiffer sway bar. The hard bushings have to transmit substantially more vibration into the mounts, which will likely lead to metal fatigue in the fairly thin stamped and welded metal mounts.
#11
2006 ASM tsx
iTrader: (1)
i actually had the same exact problem a few days ago.. and that lil bracket over the endlink was bent pretty bad. i just replaced the 10? or 12mm bolt.. and bolted it real tight.. tada the swaybar is tied down now...
i think its partially because i switched my endlinks to the moog ones.. so its way more stiffer..
that + dropping the car on basics means i have to take bumps seriously now...
at least high inclines.. like my garage alley....
soooo i'm hoping that it just doesnt go and pop off again.. or else i may have to switch back to my stock rsb?
i think its partially because i switched my endlinks to the moog ones.. so its way more stiffer..
that + dropping the car on basics means i have to take bumps seriously now...
at least high inclines.. like my garage alley....
soooo i'm hoping that it just doesnt go and pop off again.. or else i may have to switch back to my stock rsb?
#13
Originally Posted by vthree
i actually had the same exact problem a few days ago.. and that lil bracket over the endlink was bent pretty bad. i just replaced the 10? or 12mm bolt.. and bolted it real tight.. tada the swaybar is tied down now...
i think its partially because i switched my endlinks to the moog ones.. so its way more stiffer..
that + dropping the car on basics means i have to take bumps seriously now...
at least high inclines.. like my garage alley....
soooo i'm hoping that it just doesnt go and pop off again.. or else i may have to switch back to my stock rsb?
i think its partially because i switched my endlinks to the moog ones.. so its way more stiffer..
that + dropping the car on basics means i have to take bumps seriously now...
at least high inclines.. like my garage alley....
soooo i'm hoping that it just doesnt go and pop off again.. or else i may have to switch back to my stock rsb?
#14
Audi Driving Snob
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So far every single issue I've seen with broken brackets with the RSB has been with people that swtiched to Poly bushings. I had used my RSB for 4.5 years with the stock comptech bushings with no issue.
#15
I read this thread and the linked thread last night, and I checked my RSB immediately last night. No signs of stress crack. I've had mine since early 2005, the car has been on the tracks at least 5 times. As a matter of fact, I was at Laguna Seca 3 weekends ago with the TSX. My RSB worked fine as with other parts in my car (well, sort of, wished I had more aggressive brakes though). My RSB is Progress that came with polyurethane bushings. My guess is that Progress did the right thing to properly selected the bushings for their bars. I'm sure Comptech did too, maybe that was why they went with the rubber bushings instead.
#17
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Originally Posted by vwong
I read this thread and the linked thread last night, and I checked my RSB immediately last night. No signs of stress crack. I've had mine since early 2005, the car has been on the tracks at least 5 times. As a matter of fact, I was at Laguna Seca 3 weekends ago with the TSX. My RSB worked fine as with other parts in my car (well, sort of, wished I had more aggressive brakes though). My RSB is Progress that came with polyurethane bushings. My guess is that Progress did the right thing to properly selected the bushings for their bars. I'm sure Comptech did too, maybe that was why they went with the rubber bushings instead.
'04 6MT Comptech RSB, Comptech 110-115, Energy Suspension greaseable poly bushings.
Still going to check mine again, but thus far, no issues.
#18
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It seems that the chassis bracket breaking is more suceptible for those on stock suspension. Since the stock suspension is so soft and the RSB is taking so much stress. That would also explain why those that install the RSB on stock suspension notice the mod so much more than those with coilovers/springs.
#19
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Yea, but didn't gsclifton have a set of coilovers when he broke his?
I do agree with the theory of using the comptech supplied bushings with the comptech bar as opposed to switching them out to the poly ones. I think it was designed that way for a reason. I have lubed mine only twice in the 10k miles its been on my car and have had to problems with it. I checked the areas this weekend and everything is still looking good so far. I also have the aspec suspension though too, which will def help in taking more of the body movement.
I do agree with the theory of using the comptech supplied bushings with the comptech bar as opposed to switching them out to the poly ones. I think it was designed that way for a reason. I have lubed mine only twice in the 10k miles its been on my car and have had to problems with it. I checked the areas this weekend and everything is still looking good so far. I also have the aspec suspension though too, which will def help in taking more of the body movement.
#20
Racer
Thread Starter
I've been meaning to upgrade the suspension, but I have the eternal battle of the mortgage payment versus the next mod.
As expected, the dealer was no help at all, so I'm going to a muffler shop next Saturday to see if they can weld it back on and reinforce both sides.
Meanwhile, the car rides surprisingly well with no sway bar at all.
Assuming I get everything back in shape on Saturday, I'm going to re-install the Comptech sway bar with the original bushings.
As expected, the dealer was no help at all, so I'm going to a muffler shop next Saturday to see if they can weld it back on and reinforce both sides.
Meanwhile, the car rides surprisingly well with no sway bar at all.
Assuming I get everything back in shape on Saturday, I'm going to re-install the Comptech sway bar with the original bushings.
![Cross Fingers](https://acurazine.com/forums/images/smilies/xfingers.gif)
#21
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Originally Posted by jwood_06TSX
Yea, but didn't gsclifton have a set of coilovers when he broke his?
March 04, 2004 @ 5,560 miles - Shop installed Eibach Prokit with stock dampers
March 04, 2004 @ 5,560 miles - Shop installed Ingalls rear camber kit
March 11, 2004 @ 5,915 miles - Self installed Neuspeed upper strut
March 24, 2004 @ 6,275 miles - Self installed Comptech Sway w/rubber busings
Sep 23, 2005 @ 25,112 miles - Self installed ES polyurethane bushings
Dec 03, 2005 @ 27,913 miles - Self installed Cusco Type II
Jan 27, 2006 @ 28, 456 miles - Replaced damaged Cusco Type II
May 27, 2006 @ 33,350 miles - Shop installed Tanabe Sustec Pro OC Type II
Nov 22, 2006 @ 39, 102 miles - Shop installed Rays G-Games 77W 1PC 18"
Feb 21, 2007 @ ~44k miles - Detected broken sway bar mount after clunking noise
Unless you're running a relatively stiffer suspension, your RSB will probably be working harder than your dampers.
#22
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Originally Posted by HoRRo
gsclifton's mod timeline:
March 04, 2004 @ 5,560 miles - Shop installed Eibach Prokit with stock dampers
March 04, 2004 @ 5,560 miles - Shop installed Ingalls rear camber kit
March 11, 2004 @ 5,915 miles - Self installed Neuspeed upper strut
March 24, 2004 @ 6,275 miles - Self installed Comptech Sway w/rubber busings
Sep 23, 2005 @ 25,112 miles - Self installed ES polyurethane bushings
Dec 03, 2005 @ 27,913 miles - Self installed Cusco Type II
Jan 27, 2006 @ 28, 456 miles - Replaced damaged Cusco Type II
May 27, 2006 @ 33,350 miles - Shop installed Tanabe Sustec Pro OC Type II
Nov 22, 2006 @ 39, 102 miles - Shop installed Rays G-Games 77W 1PC 18"
Feb 21, 2007 @ ~44k miles - Detected broken sway bar mount after clunking noise
Unless you're running a relatively stiffer suspension, your RSB will probably be working harder than your dampers.
March 04, 2004 @ 5,560 miles - Shop installed Eibach Prokit with stock dampers
March 04, 2004 @ 5,560 miles - Shop installed Ingalls rear camber kit
March 11, 2004 @ 5,915 miles - Self installed Neuspeed upper strut
March 24, 2004 @ 6,275 miles - Self installed Comptech Sway w/rubber busings
Sep 23, 2005 @ 25,112 miles - Self installed ES polyurethane bushings
Dec 03, 2005 @ 27,913 miles - Self installed Cusco Type II
Jan 27, 2006 @ 28, 456 miles - Replaced damaged Cusco Type II
May 27, 2006 @ 33,350 miles - Shop installed Tanabe Sustec Pro OC Type II
Nov 22, 2006 @ 39, 102 miles - Shop installed Rays G-Games 77W 1PC 18"
Feb 21, 2007 @ ~44k miles - Detected broken sway bar mount after clunking noise
Unless you're running a relatively stiffer suspension, your RSB will probably be working harder than your dampers.
![Thumbs Up](https://acurazine.com/forums/images/smilies/thumbsup.gif)
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#27
Racer
Thread Starter
Originally Posted by gavinn58
Well, you can add me to that list of broken chassis mount. Can anyone tell me how much it was to repair?
I found an awesome shop here in the Bay Area that fabricates sway bar mounts for Bimmers, Porsches, and S2000s. They also do custom fabrication and welding, so it was no sweat for them to put everything back into order and to reinforce both sides. It was $100.
Your situation looks a little hairier to me, but if you can find somebody who does fabrication and welding -- not just a muffler shop -- I think they can fix you up. I feel for you, man.
#28
Racer
Thread Starter
Originally Posted by GTSX-05
ouchh, I hope I dont experince the same problems with my H&R that hasnt been installed.
That said, plenty of guys have a RSB and haven't had any problems.
#29
Originally Posted by green_henry
Ouch, that looks worse than mine did. Mine broke at the weld spots so that the bracket itself was basically intact -- just separated from the chassis.
I found an awesome shop here in the Bay Area that fabricates sway bar mounts for Bimmers, Porsches, and S2000s. They also do custom fabrication and welding, so it was no sweat for them to put everything back into order and to reinforce both sides. It was $100.
Your situation looks a little hairier to me, but if you can find somebody who does fabrication and welding -- not just a muffler shop -- I think they can fix you up. I feel for you, man.
I found an awesome shop here in the Bay Area that fabricates sway bar mounts for Bimmers, Porsches, and S2000s. They also do custom fabrication and welding, so it was no sweat for them to put everything back into order and to reinforce both sides. It was $100.
Your situation looks a little hairier to me, but if you can find somebody who does fabrication and welding -- not just a muffler shop -- I think they can fix you up. I feel for you, man.
![Thumbs Up](https://acurazine.com/forums/images/smilies/thumbsup.gif)
also if you could snap a few pics of the repair and reinforcement job they did on your car, that would be great. i'd like to see their handy work.
#30
Racer
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just a quick question to those who had their mounting bracket broken, does the car act weird other than that "clunk" noise you hear? i'm asking this because i've been hearing this "clunk" noise too with my car whenever i go over certain road surface. But other than that clunk noise my car drives fine..
#31
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I have the Progress RSB installed and so far no problems so far <knock on wood>. But since you are in Northern California I would be interested in knowing the shop's name too. Just in case my mounts break....
#32
Racer
Thread Starter
Originally Posted by CL9projektz
would you mind sharing the shop's name/contact info/location/etc? thanks. ![Thumbs Up](https://acurazine.com/forums/images/smilies/thumbsup.gif)
also if you could snap a few pics of the repair and reinforcement job they did on your car, that would be great. i'd like to see their handy work.
![Thumbs Up](https://acurazine.com/forums/images/smilies/thumbsup.gif)
also if you could snap a few pics of the repair and reinforcement job they did on your car, that would be great. i'd like to see their handy work.
I'd need to jack the car up to get some decent pics. Too busy now, but I'll try to make time next weekend.
#33
Originally Posted by green_henry
Ouch, that looks worse than mine did. Mine broke at the weld spots so that the bracket itself was basically intact -- just separated from the chassis.
I found an awesome shop here in the Bay Area that fabricates sway bar mounts for Bimmers, Porsches, and S2000s. They also do custom fabrication and welding, so it was no sweat for them to put everything back into order and to reinforce both sides. It was $100.
Your situation looks a little hairier to me, but if you can find somebody who does fabrication and welding -- not just a muffler shop -- I think they can fix you up. I feel for you, man.
I found an awesome shop here in the Bay Area that fabricates sway bar mounts for Bimmers, Porsches, and S2000s. They also do custom fabrication and welding, so it was no sweat for them to put everything back into order and to reinforce both sides. It was $100.
Your situation looks a little hairier to me, but if you can find somebody who does fabrication and welding -- not just a muffler shop -- I think they can fix you up. I feel for you, man.
#35
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Originally Posted by green_henry
Ouch, that looks worse than mine did. Mine broke at the weld spots so that the bracket itself was basically intact -- just separated from the chassis.
I found an awesome shop here in the Bay Area that fabricates sway bar mounts for Bimmers, Porsches, and S2000s. They also do custom fabrication and welding, so it was no sweat for them to put everything back into order and to reinforce both sides. It was $100.
Your situation looks a little hairier to me, but if you can find somebody who does fabrication and welding -- not just a muffler shop -- I think they can fix you up. I feel for you, man.
I found an awesome shop here in the Bay Area that fabricates sway bar mounts for Bimmers, Porsches, and S2000s. They also do custom fabrication and welding, so it was no sweat for them to put everything back into order and to reinforce both sides. It was $100.
Your situation looks a little hairier to me, but if you can find somebody who does fabrication and welding -- not just a muffler shop -- I think they can fix you up. I feel for you, man.
#36
9th Gear
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I can be added to the list of broken rear subframes. I had the Comptech RSB with ES bushings (w/o grease fitting) and stock suspension on my 05. I had mine on for just over a year. I agree with the comment that installing the comptech RSB with stock suspension puts too much strain on the rear sub frame.
#38
Three Wheelin'
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You need to consider a lot of things here though. Most of the people that have broken them were on stock suspension, at least the two people in this thread were. They were also running the non matching poly bushings with them as well. I think the combination of adding the harder bushings (taking away some flexibility) and not upgrading suspension (firmer dampers and springs to take more load than the stock ones) is what puts more force into these mounts. If you have the CT bushings and an aftermarket suspension AND lube them every so often, i really don't forsee a problem.
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#40
Racer
Thread Starter