Put on the front KYB struts with strut boot over the weekend and, with everything put back correctly, have a noise that sounds like metal on metal...advice please!? Is there something I forgot (ie new strut mounts from KYB?) I'm in a bind!

 

Does the metal on metal sound come from somewhere under the driver's seat?

 

No, it sounds like near each shock, no sure of origin. Why do you ask under the driver seat?

 

There is a headlight level module under the car under the driver's seat. It is known to make a scraping sound. Mine made the noise when a passenger got into the car.

Then one day it quit making the noise, so I am not sure how to fix it.

 

Did you torque everything with the car suspended and knuckles hanging or supported at ride height? Either way, I would go back under the car and re-torque everything. Look for any parts that have rubbed while you're under there.

Is it a rotational sound? When is the sound present?

 

Not a rotational sound, mostly on bumps, but not on smooth pavement...What the*

 

I just changed to coil overs and I'm experience the same noise. I probably forgot to torque something correctly...

 

Recheck your sway bar links as well. My rear links drive me mad for a long time. I had checked and they seemed tight to the rear sway but eventually discovered they were the source of metallic clink noises. Took a Chassis Ear to locate the noise source was at the sway bar to link hardware.

 

Here is another one you'll need to check, the top nut on the strut, make sure you torque it to specs after the spring settles.