Last weekend I did a complete front end overhaul on my wife's 2005 Grand Prix (base model) w/ 107,000mi. I used Amazon for everything except the struts and end links. I ended up getting Dorman 520-165/166 LCAs since according to their parts finder it was a fit. Of course they fit, but I didn't know there was a tab for a different style sway bar link. So I figured I just wouldn't use the mounting point on the LCA and stick with the original type of links that bolt onto the strut. There's about a 3 inch space between the LCA tabs and the original sway bar end links. When I jack the front end up the end link binds on the LCA tab as it comes into contact with it.
Took it on a test drive and it sounds like I have broken links on both sides. Cornering, hitting bumps, etc... I get clunk, clunk, clunk and feel rattling in the front end. I reinspected the end links and they are in good shape, only 2 days old. I reinstalled them and used a torque wrench this time to be sure they were tightened to spec. Still getting clunk, clunk, clunk, from both sides. It 100% sounds to me like what broken end links sound and feel like. So my theory is they're hitting the tabs on the LCA.
Has anyone successfully used older style LCAs but kept the original sway bar end links? Could this be the problem? Maybe the sway bar bushings instead? I don't want to upgrade the sway bar since I bought new links that I've already installed.
I was thinking about just taking my dremel and cutting the LCA tabs off, but didn't want to if I didn't have to.
