I have a 2010 PTT that has had upper and lower control arms, and sway bars changed for crunching noises heard over speed bumps. Happens when the ambient temp is less than 30 F. Still no better. Will keep until the warranty runs out next year.

Questions:
1) Does this happen on later model PTT?
2) Does this happen on non turbo models?
3) Is it only a cold climate issue ?

Just trying to figure out if i should bother with another PTT..........

 

I am experiencing the same thing in my 2010 4s so not exclusive to the PTT. I spoke with my service manager about it at my local dealer. He did not hesitate when I mentioned it. He says the bushings have to be replaced and a front end alignment to fix the issue. My issue is not limited to cold weather. I have not had the work completed yet. I am out of warranty so I have not rushed to go and have this done. I only hear it periodically. He tells me that it isn't anything dangerous at this point so I will get it fixed within the next couple of months.

 

I have had this same problem this winter. I picked up my 2011 PTT in October and when the temperature dropped I heard the same crunching noise. I thought I was driving the car too fast over bumpy roads. It was so bad that the car would creak even from braking and accelerating from a full stop. Granted, it only happens once the temperature drops, but we have been having some really cold days here in Toronto, close to -30C and hearing that noise is unbearable when it is cold. I've noticed there when the temp is starts to creep below -17C. I'm waiting on parts from Germany and I'll let you know how it goes. Fortunately my car is still under warranty. Same issue - some rubber brushings and suspension parts need to be changed.

 

Bumped into this: WM 400150 (Workshop Manual document).

It says to try to re-tighten the lock nuts on the camber and caster eccentric adjusters, basically the front and rear M12 x 1.5 bolts that connect the lower control arm to the subframe.

Specification for both: 50 Nm (37 ft-lb), and then + 120 degrees.

Would be interesting to poll how many cars this actually works on. May just try this tomorrow if I get a chance!!!

 

Here is your solution, stabilizer bar bushings, sound will be gone completely. I changed upper and lower arms and sway links and still had crunch sound in cold weather, bushings eliminated the sound all together. $50 fix