my suspension setup Illumia with maxspeed springs, ES sway bar bushings and endlinks.

so i was driving today the same routes i do everyday, its not exactly smooth with the chicago salt and etc. so there was a good amount of bumps and potholes. I was slowing down to make a right turn and i heard this thud noise pretty constant sounded like i had a flat tire on front pass side. So i pulled over to check it out, i was almost certain that i had a flat tire by the way it sounded. SUPRIZE nothing was wrong. i took a quick look over the suspension but my hand on the axle to see if the CV axle popped.

So i was driving along and the noise was always present. Everytime i would go over uneven ground it would have a thud noise, I swear it sounds as a flat tire. But on smooth roads the car drove normal. Then i made a large left turn and the noise was present. i did the same turn but making a right and nothing.

Finally got home, first thing jack up the right side take off tire. Confirmed tire was still in great shape and fully round, then my next choices were sway bar, endlinks and bushing looked clean and in place. Next on to the axle, inner outer boot not blown, I felt the outer boot to make sure the CV axle didn't jump out of its cage. So nothing, everything seemed to be fairly decent. Obvious it was a suspension problem, i looked over the strut and the way the spring sat. it was in the grove so everything is a gold. I checked the wheel once more and rotated it to the rear driver's. Put the wheel on and drove it around the block. Same results happened. As i sat down and thought, i remember i left out the paper spacer for the struts in the front. I forgot to order then and then i left the old ones out. Also i recalled i got Gabriel strut mounts from autozone and i heard people having issues with their struts. So i go and put down on the fenders. Sure enough i had a sound on the pass front.

a good thud and movement if you placed your hand over the illumia's adjustable piston. None on the driver's side. So i guess i found my problem. Question is now, what exactly would need to be replaced...

I figured the paper gasket. Maybe whole new mount/ bearing as i can't pin point what exactly is wrong. I'm thinking about just putting on the old OEM ones for now as i didn't have a problem with them what so ever.

 

It's not the paper gasket. If your mounts are new, there probably fine as well.
Both of my Illuminas make a knocking sound, I believe it's the valvebody inside the strut. It's not to loud, you can hear and sort of feel it if you push down on the fender with your finger on the strut adjuster. I've had the whole suspension apart, everything is tight and the strut also feels fine when it's disassembled, yet the noise continues. I will be replacing them with a set of the Blues this spring.