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      02-28-2018, 01:36 PM   #1
dre99gsx
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Powerflex FCAB Failure

These had about 4 HPDE sessions (1 year) of use. Felt something loose in the front end today when doing heavy braking.

These were PFF5-4601 "Street Compound" I believe.

Anyone else had this happen to them? I'm starting to suspect this will be a new wear item along with pads

Are there better brands out there aside from going back to OEM?

Also, yes this is the passenger side which is right next to my exhaust (although not directly next to it, still has heat shield over it...)
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      02-28-2018, 01:43 PM   #2
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Whiteline, and consider a heat shield. I had similar issues with powerflex.
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      02-28-2018, 01:47 PM   #3
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The oem heatshield is still there, which I assume is supposed to help protect that exact component. I could add some additional heat protection, and probably will next time around.

Also, I don't believe Whiteline makes them for E46 non-M (3.0si)...
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      02-28-2018, 01:48 PM   #4
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This is not wear but overstrain/overload to the point the rubber tears.

Maybe try the powerflex black series. they're shore95a and maybe stronger (as the PU is stiffer/harder, it may be able to withstand more force).

You need a style of bushing that can carry the surfaceload, so made with an inner core material that can stand more N/mm˛

I know hardrace makes a lollypop with a Polyetherimide core, which is very hard. (obviously the harder the fcab, the more NVH). Turner probably has something similar in Delrin or such.

Did you use enough of the supplied copper grease? The knurling on the inner bushing needs to be saturated with grease (it acts as a grease trap)
I see some grease but no copper coloured grease. Or has powerflex changed the type of grease they ship it with recently? (last powerflexstuff I got/installed is already 2 years ago)

Anyway you can get a replacement for free as they offer lifetime warranty I believe. Maybe you can get the black ones for free
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Last edited by GuidoK; 02-28-2018 at 02:10 PM..
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      02-28-2018, 02:24 PM   #5
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I installed it with the supplied grease, used quite a bit of it too. I don't recall if this was a copper compound though. It's not the first time I've installed these on other vehicles thus I'm fairly familiar with what is required, but, it's possible they supplied something else.

I'm hesitant on going even harder durometer since I still drive this on the street and it is too stiff as it is.

Waiting for Powerflex to respond, although their warranty states racing is not covered (hpde isn't racing, but it's a gray area...)

Judging by the way this just fell apart as I removed it, could be heat. Look at how one part of the purple center has the PU just pealing off...
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      02-28-2018, 02:54 PM   #6
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Sorry to see that, Andre! My local race shop recommend and installed the Black Powerflex bushings for this reason. Maybe give those a try? I put these on with solid motor/transmission mounts along with Turner Track rear camber arms and honestly NVH still is not that bad.

Edit - Here is a photo of what we went with:
http://scontent-lga3-1.cdninstagram....79056896_n.jpg
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      02-28-2018, 03:34 PM   #7
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Thanks. Black series is a month door-to-door ship from MFG (don't see any US dealers with this in stock). I need something for next session coming up in 2 weeks, thus will have to go Purple again.

Also street price $220 vs $85.. but, I will consider them if/once these next Purples fail.
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      02-28-2018, 04:11 PM   #8
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Quote:
Originally Posted by dre99gsx View Post
Thanks. Black series is a month door-to-door ship from MFG (don't see any US dealers with this in stock). I need something for next session coming up in 2 weeks, thus will have to go Purple again.

Also street price $220 vs $85.. but, I will consider them if/once these next Purples fail.
I got mine from ECS last week with no problems but I do see your point since they are drop shipped. Missed out on their current sale, looks like they are $204 this week.

Going to the PCA event on the 17/18? If so, I might see you there (watching the weather)!
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      02-28-2018, 05:51 PM   #9
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Yes I am! Hopefully weather is good, but I'll come find you as I'm always on the hunt for a fellow Z4 Plan to do a few more this year but haven't signed up yet.
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      03-01-2018, 12:41 PM   #10
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Why do people still use Powerflex? I've heard nothing but failures and premature fatigue.

Go with AKG.
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      03-01-2018, 12:53 PM   #11
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Quote:
Originally Posted by Eson View Post
Why do people still use Powerflex? I've heard nothing but failures and premature fatigue.
I've had the purple powerflex fcab's now on for 7 years and 30k+ miles. (mine is of the previous generation design compared to the TS version)
They still look like new and dont squeak.

after 7 years/30k+ miles:



Quote:
Originally Posted by dre99gsx View Post

Also street price $220 vs $85.. .
http://www.ebay.co.uk/itm/BMW-Z4-E85...S/191483359463

Ł64 shipped to US. (about $88 I believe) (but shipping is likely to take more than 2 weeks)
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Last edited by GuidoK; 03-01-2018 at 01:05 PM..
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      03-01-2018, 01:09 PM   #12
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Quote:
Originally Posted by dre99gsx View Post
The oem heatshield is still there, which I assume is supposed to help protect that exact component. I could add some additional heat protection, and probably will next time around.

Also, I don't believe Whiteline makes them for E46 non-M (3.0si)...
http://www.whiteline.com.au/product_...=W52584&sq=874

The formulation that WL uses is superior to PF. They also make offset ones for the m.
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      03-01-2018, 01:20 PM   #13
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Quote:
Originally Posted by angelr View Post
That one doesnt fit. its the wrong one.
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      03-02-2018, 03:19 AM   #14
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Millway in Sweden makes a great FCAB with a mix of aluminium, delrin and poly. Their website server provider seems to have a problem right now though. I'll link it when it works. It's about 175$ for the pair.
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      03-02-2018, 03:51 AM   #15
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You mean this one:
http://www.millway.se/front-control-...fcab-66mm.html

With the greasenipple
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      03-02-2018, 01:09 PM   #16
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Quote:
Originally Posted by GuidoK View Post
That one doesnt fit. its the wrong one.
Both size housings, offset and centered.

http://www.whiteline.com.au/product_...=W52584&sq=874

http://www.whiteline.com.au/product_...=W53518&sq=875

http://www.whiteline.com.au/product_...=W52605&sq=876

http://www.whiteline.com.au/product_...=W52606&sq=878
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      03-03-2018, 03:20 AM   #17
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Quote:
Originally Posted by GuidoK View Post
You mean this one:
http://www.millway.se/front-control-...fcab-66mm.html

With the greasenipple
That's the one! Millways makes great stuff. By car enthusiasts for car enthusiasts. Some if their stuff are a bit pricey but the quality is second to none.

I use all Millway bushings in my Z3 Coupe race car (except for engine and gearbox mounts). The only product from Millway I haven't installed on my Z3 Coupe yet is their DTM-kit for the rear trailing arms.
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      05-08-2018, 07:35 PM   #18
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UPDATE:

After 2 hpde weekends on these new FCABS - AKG Motorworks 66mm 95a Poly (stiffer than my original Powerflex), I now notice about 1mm of sideways play between the inner bushing and the outer bushing as I wiggle the front wheel sideways.

I did notice my brake pedal drop a bit on very tight turns (still had brake pressure), and wondering if this was related. And, do any of you get any play at all on your FCABS?

Driver-side is still solid.

The passenger wheel must get a beating out there. Within one year, went through two wheel bearings, and obviously the Powerflex FCAB failure.
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      05-11-2018, 02:50 AM   #19
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I doubt its the heat, Ive been running mine for 2 seasons now, and it doesn't get hotter anywhere then where I live. My last session I had to retire as it was getting to hot. Everything gets really hot on mine, zero failure.. (so far anyhows) I do think its a consumable part, but 4 sessions isn't much... bloody hell.. 2 wheel bearings??
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      05-12-2018, 09:00 PM   #20
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Did some measurements on the passenger FCAB from AKG. The larger "press-in" bushing has two inner diameters. The smaller where there are grooves for grease, and the outer where the smaller bushing lip inserts into.

Driver side (good): 47.30mm ID
Pass side (bad): 48.30mm ID

The pass side looks great, but because of the enlarged radius (1mm), the center bushing moves around. I suspect the large pressed-in poly expanded from abuse (or some heat.. although Vanne brings up an interesting point.)

AKG states lifetime warranty, I'll have to run this by them on what's going on here. Wasn't planning on buying new FCABS every other event Hell, even the OEM FCAB on the passenger side was completely obliterated when I purchased the car. Driver-side fcab was still fresh and tight

Yeah - two wheel bearings, but I believe they were Chinese brand. I replaced with OEM two sessions ago, still holding up. I suspect it is Ok for now.

Still, the right-front of my car is high maintenance! lol
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      05-12-2018, 10:25 PM   #21
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Quote:
Originally Posted by dre99gsx View Post
Did some measurements on the passenger FCAB from AKG. The larger "press-in" bushing has two inner diameters. The smaller where there are grooves for grease, and the outer where the smaller bushing lip inserts into.

Driver side (good): 47.30mm ID
Pass side (bad): 48.30mm ID

The pass side looks great, but because of the enlarged radius (1mm), the center bushing moves around. I suspect the large pressed-in poly expanded from abuse (or some heat.. although Vanne brings up an interesting point.)

AKG states lifetime warranty, I'll have to run this by them on what's going on here. Wasn't planning on buying new FCABS every other event Hell, even the OEM FCAB on the passenger side was completely obliterated when I purchased the car. Driver-side fcab was still fresh and tight

Yeah - two wheel bearings, but I believe they were Chinese brand. I replaced with OEM two sessions ago, still holding up. I suspect it is Ok for now.

Still, the right-front of my car is high maintenance! lol
Back off the curbing a little lol

You sure your alignment is good?
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      05-12-2018, 10:29 PM   #22
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I do use the curbing that's for sure! Although, it's not that bad at NJMP.

Positive on the alignment, I do my own alignment and corner balancing before every event.

I just ordered the Monoball from Turner. Going to give that a shot. Expensive, but I don't want to keep worrying about these things. If the monoballs go, then I'll stay off the curbing
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