Ivanerrols W204 front end issue

1993-Present: C200 CDI, C220 CDI, C270 CDI, C180, C200 Kompressor, C230 Kompressor, C220, C230, C280, C300 C350, CGI & CDI BlueEfficiency variants
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Ivanerrol
Mercedes Demigod
Posts: 5546
Joined: Sat 12 May, 2007 3:21 pm
Model you own: w204
Location: Melbourne

Ivanerrols W204 front end issue

Post by Ivanerrol » Sun 03 Sep, 2017 12:44 am

A story that will grow in the telling.
The W204 C280 has front end noises. Clunking and grinding
41,000 kilometers. 2009 build date.

The 204 front suspensions have two lower control arms, Macpherson struts and a sway bar with link ends.
My car being a six cylinder comes with 17 inch staggered sports wheels with low profile tyres.

When buying this car the P.O. was at pains during the test drive to show off the Harmon Kardon audio system. probably to distract me from the noise that the front suspension was making - more fool me. :whistle:

Isolation so far.
Suspecting tyre noise I swapped the 17 inch wheels and tyres for the Continentals Contact 2's I have on the W210 - the W210 tyres being very quiet.
The W204 tyres went onto the W210 - they're Continental Sports contact 5's very good tyres and very quiet.
So - not the tyres and wheels.

Sway bar links and sway bar bushings. Overseas experience has shown that the links are a source of noise.
I have removed the links and bought new OEM ones.
Driving around without the swaybar being connected at all.
The clunking sound seems to have diminished but not entirely gone away.

Tomorrow I will inspect and if necessary replace the wheel bearings. Overseas experience has shown that there is a slight design flaw in the ABS sensor seal that lets moisture into the rear bearing and resultant rust is an issue.
We will see.
There's a TSB for this but no recall - in Australia.

While at the stealership this morning, the parts guy informed me that the McPherson strut top mounts have been redesigned.
I suspect that this maybe an issue in my car. The original design failing prematurely.
There's also a TSB for this issue - no recall in Australia. Replaced if car under warranty. Car out of warranty - owners pay.

To be continued.
W211 - E240
W204 - C280
W202 - C180
W210 - E240
Departed
W202 - C200
W202 - C180 - On consignment to nephew
W126 - 380SE , 380SE (Ex SA Import), 560SEL
W124 - 300e, 260e (ex Japan)
W111 220s (Indonesia) 4 speed manual column shift
W123 230
W116 450SEL
W140 420SEL
W210 E240
W209 CLK 240
W201 190e 2.6 (ex U.K.)

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Bartman4800
300 SLR
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Joined: Fri 10 Oct, 2008 12:10 am
Model you own: w111
Location: Perth WA

Re: Ivanerrols W204 front end issue

Post by Bartman4800 » Wed 06 Sep, 2017 2:00 pm

I am not familiar with this model. But I had a 99 Camry V6 before. I replaced the front MC pherson struts and then got a groaning noise going over speed humps. My local auto-one employs real mechanics, and one of them suggested soaking the top mount with inox.
It worked for 2 years until my girlfriend totalled the car...

Bart
1963 220 Sb Sedan "Kermit" (Australian Assembly)
1960 220 Sb Sedan "Zum Schlachten" (Early German Assembly, with a torsion bar spring for the bonnet) - Stored in Country WA
1981 Subaru Brumby 1.8 with Weber and 5-speed box "little utie" - Sold to another enthusiast!
2006 Ford Focus "missus car"
2002 VW Passat V6 30V Station Wagon (my new commuter bus)

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dturner44
Posts: 2
Joined: Tue 28 Jul, 2015 5:37 pm
Model you own: w203

Re: Ivanerrols W204 front end issue

Post by dturner44 » Fri 15 Sep, 2017 6:08 pm

My 2010 C250 CGI had front suspension knocks at approx. 35,000 Ks. It was caused by faulty valves in the front struts. This model has Agility Control suspension which senses different road conditions and adjusts the suspension damping accordingly. The valves were known to be faulty but MB didn't do a recall, however I believe that if you complained whilst under warranty they did replace the front struts. I had my struts (with redesigned valving) replaced under a used car warranty when I bought the vehicle, problem fixed. You should check if the 2009 model has the same suspension.

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Ivanerrol
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Posts: 5546
Joined: Sat 12 May, 2007 3:21 pm
Model you own: w204
Location: Melbourne

Re: Ivanerrols W204 front end issue

Post by Ivanerrol » Fri 15 Sep, 2017 10:55 pm

dturner44 wrote:
Fri 15 Sep, 2017 6:08 pm
My 2010 C250 CGI had front suspension knocks at approx. 35,000 Ks. It was caused by faulty valves in the front struts. This model has Agility Control suspension which senses different road conditions and adjusts the suspension damping accordingly. The valves were known to be faulty but MB didn't do a recall, however I believe that if you complained whilst under warranty they did replace the front struts. I had my struts (with redesigned valving) replaced under a used car warranty when I bought the vehicle, problem fixed. You should check if the 2009 model has the same suspension.
My car does have Agility Control with a switch setting :whistle:
Probably just another under engineered addition. :Doh:

I'll check this out. Thanks for the tip DTurner.

Meanwhile.
I changed the drivers side front wheel bearing. Not only were the bearings scored but the hub also. New Hub required $$$$$$
And then there's the axle spindle.
bearing 02.JPG
Note that metal failure. It's not just rust.
I showed this to the guys down the local stealership. This spindle should have never made it onto the car - which begs the question - quality control :wave:

I'm up for a new axle/spindle stub - Stealership cost $1000.00 incl GST.

Another under engineered issue. MB changed the position of the ABS sensor. original W204's came with ABS sensors with faulty sealing.
The faulty sealing let water ingress to the rear bearing on the front wheels causing them to rust out.
There's a TSB on this. New type seal should be changed at service time.

The stealership guys gave me a new seal for the ABS sensor - before I put the new bearing hub on.

Changing the wheel bearing made a big difference to the rumbling noise situation.

Tip from old mechanic.

To find suspension noises.

Grab hold of the spring.

Rotate the wheel - if you can feel the rumbling sensation through the spring you know your bearings are suspect.

Get a mate to use a pry bar and test each LCA and ball joint. You will feel faulty issues through the spring.
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W211 - E240
W204 - C280
W202 - C180
W210 - E240
Departed
W202 - C200
W202 - C180 - On consignment to nephew
W126 - 380SE , 380SE (Ex SA Import), 560SEL
W124 - 300e, 260e (ex Japan)
W111 220s (Indonesia) 4 speed manual column shift
W123 230
W116 450SEL
W140 420SEL
W210 E240
W209 CLK 240
W201 190e 2.6 (ex U.K.)

stefcep
B Class
Posts: 19
Joined: Sun 16 Dec, 2012 11:24 am
Model you own: w202

Re: Ivanerrols W204 front end issue

Post by stefcep » Sun 10 Dec, 2017 2:08 pm

Have you fixed all of this Errol?

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Ivanerrol
Mercedes Demigod
Posts: 5546
Joined: Sat 12 May, 2007 3:21 pm
Model you own: w204
Location: Melbourne

Re: Ivanerrols W204 front end issue

Post by Ivanerrol » Sun 10 Dec, 2017 3:24 pm

stefcep wrote:
Sun 10 Dec, 2017 2:08 pm
Have you fixed all of this Errol?
Not yet.
I'm contemplating the W204's future.

(a) Needs new front knuckles and axle spindles - both sides.
(b) Needs new wheel bearing hub and bearings one side front.
(c) Needs new strut mounts - they're roller type plus the fixings to hold everything together.
(d) Needs front torque bars both sides
(e) Needs new front brake shield back mounts which contain revised water seals
(f) Engine has a misfire when cold
(g) Rear lights require new circuit boards and rewiring - a very labor intensive job
(h) Transmission clunks at highway speed when lifting off the accelerator and then putting your foot down again (suspect software issue)
(j) Alarm has come up indicating Service C required.

Car has 42,000 kms on it.

The stealership costs to fix all of the above is more than the price I just paid for a 2004 W211 with 84,000ks on it.
If I do all that work myself using a combination of imported and local sourced parts this will still be 60% of the stealers cost.
W211 - E240
W204 - C280
W202 - C180
W210 - E240
Departed
W202 - C200
W202 - C180 - On consignment to nephew
W126 - 380SE , 380SE (Ex SA Import), 560SEL
W124 - 300e, 260e (ex Japan)
W111 220s (Indonesia) 4 speed manual column shift
W123 230
W116 450SEL
W140 420SEL
W210 E240
W209 CLK 240
W201 190e 2.6 (ex U.K.)

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Tony From West Oz
OZBENZ moderator
Posts: 3089
Joined: Mon 20 Jun, 2005 10:04 pm
Model you own: w202
Location: Bedfordale WA

Re: Ivanerrols W204 front end issue

Post by Tony From West Oz » Sun 10 Dec, 2017 6:32 pm

The "modern" Mercedes Benz are just like the rest of the car world - Throw away cars.
Life is a journey, with problems to solve, lessons to learn, but most of all, experiences to enjoy.

'83 W123 300D 325000km (Wife's car Josephine - sold).
'84 W123 300D replaced good OM617 912 with OM617 952 and enjoyed having good acceleration for the first time since first driving a 300D in 2002 - became engine and trans donor for 300CD Turbodiesel conversion. Now parted out.
'86 W124 300D sold (Wife's old car - sold )
'85 W123 300CD, 275 000km (Fatmobile) rebuilt turbodiesel from previous Fatmobile transplanted into 280CE (occasional tourer)
'99 W202 C250 Turbodiesel (my darling Wife's car - Sold)
'98 W202 C250 Turbodiesel (my car - Sold)
'06 Ssanyong Musso Crew Cab 2WD Ute (OM662 diesel and Auto Transmission)

stefcep
B Class
Posts: 19
Joined: Sun 16 Dec, 2012 11:24 am
Model you own: w202

Re: Ivanerrols W204 front end issue

Post by stefcep » Mon 11 Dec, 2017 6:24 pm

that's really disappointing that a car with so few Km's can have those sorts of issues.

Last month cousin just dropped over $100k on a new 2017 AMG C43. He had an older CLK, and said the new ones aren't made the same. He wondered if the buyer of the CLK would sell it back to him....

newMercowner69
S Class
Posts: 80
Joined: Tue 24 Feb, 2015 5:00 pm
Model you own: w202
Location: Melbourne, Australia

Re: Ivanerrols W204 front end issue

Post by newMercowner69 » Thu 14 Dec, 2017 7:19 pm

If you need new bearings let me know,
I can supply cheaper than "stealership",
Also can possibly supply the strut mount bearings.BTW/fyi BEWARE of cheap inferior Chinese made copies of the GENUINE, O.E.M. MB wheel bearings which are FAG brand,
Have been since the very 1st model.EXCEPT for needle roller & idler/tensioner bearings &clutch &auto electrical bearings they're INA & NSK respectively,
Because the starter motor&alternator&A/C are Bosch & jap compressors ,
Bosch use jap bearings in there auto electrical components.

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