My girlfriend's 02 S40 has developed a rattling noise coming from the front passenger side. It's pretty intermittent but I think it's been getting worse. It doesn't seem to be directly related to the suspension, although it only happens when the car is in motion. I've tried bouncing up and down on the bumper and pushing back and forth but can't seem to reproduce anything. Could this be something like a loose hood liner or should I keep focusing on the suspension?

 

Nothing?

 

How about turning does that make it happen?

Also is it a muffled rattle or like a louder metal type rattle?

 

Loud, metal on metal. Happens going straight or around corners. It was initially fairly intermittent (actually seemed to go away for a few weeks), but now it's pretty constant.

 

Maybe the sway bar bushing fell apart.

 

It's handling a bit funny too. Found a copy of the 2005 version of VADIS online to try and look for some diagrams of the suspension. Is it just me or is that software mind-numbingly bad?

 

It is a little of a pain to get used to but once you learn it you can look up any info you would ever need.

When you set it up did you select all options?

 

I believe I went with recommended, which was still the longest install of any software I've ever used. Is there anyway to get that dust boot off without taking the shock off the car? The sound definitely seems to be coming from that general area, but everything visible looks ok.

 

No way to get the dust book off with out removing it. Also the upper breaing plate might be bad. I have looked up there before with a small mirror and seen them bad.

On Vadis I meant when you created the new user did you select all in there. If not then you might only have access to minor things.

Vadis is like 3 gigs in size.