I made some thicker top bushings for the front shocks and voila! all quiet.
When I removed the KYB bushings, I looked at the underside of the metal
cup.  It was clear the shoulder of the shock was banging on the bottom of
the cup and the nut was marking the top side. The thin bushing was allowing
some movement both ways.  The new bushings I made are about 1" thick, which
is more than you really need.  Reusing the stock VW bushings and cups would
probably work if they are a little thicker and still in good shape.  (For
you lab rats, I made the bushings out of two No. 10 rubber stoppers.
No. 9s would probably be perfect, but I didn't have any laying around!)  I
now have about three threads exposed instead of 1/2" or more.  The thicker
bushing allows the nut to draw the shock up tight against the upper A-arm,
so there is no banging either way.

            Jay

This communication is for use by the intended recipient and contains
information that may be privileged, confidential or copyrighted under
applicable law.  If you are not the intended recipient, you are hereby
formally notified that any use, copying or distribution of this e-mail,
in whole or in part, is strictly prohibited.  Please notify the sender
by return e-mail and delete this e-mail from your system.  Unless
explicitly and conspicuously designated as "E-Contract Intended",
this e-mail does not constitute a contract offer, a contract amendment,
or an acceptance of a contract offer.  This e-mail does not constitute
a consent to the use of sender's contact information for direct marketing
purposes or for transfers of data to third parties.

 Francais Deutsch Italiano  Espanol  Portugues  Japanese  Chinese  Korean

            http://www.DuPont.com/corp/email_disclaimer.html