I saw this Cobalt tech tip today and thought it might apply to our HHR's Food for thought, anyway.


Owners of a 2008 Chevy Cobalt may note a clunk or thump noise from the front suspension while driving over rough road surfaces. The noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke. The condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses its position due to oil being deposited onto the retention fingers. The oil is from a leaking strut.

If oil is present, replace the affected strut, jounce bumper and dust boot. Before reassembling the strut assembly, glue the new jounce bumper and new dust boot to the upper spring seat.

Clean the upper spring seat surface area using fine sandpaper. Apply a light coat of 3M automotive adhesion promoter part number (P/N) 06396 or equivalent to the top of the dust boot shield on the inside edge and to the top of the bumper. Allow it to dry for 10 minutes.

Glue the bumper to the inside of the dust boot using 3M Duramix Super Fast Adhesive. Allow it to cure thoroughly 5-10 minutes at room temperature. Apply a light coat of 3M automotive adhesion promoter to the top of the dust boot and to the upper spring seat surface. Allow it to dry for 10 minutes.

Glue the dust boot shield to the upper spring seat. Allow to completely dry.

 

Thanks for the tip, most just slow down for the potholes, train tracks , speed bumps .

 

Actually turns out that was design flaw. They used to sell front struts as "fits Cobalt and HHR" They made noise on HHR, after-market vendors redesigned a special part for HHR that does fit both without the noise. Look for the asterisk after the part number on the box.