The shock collar on my right front is sticking up about 1/8" past the top of the rubber bushing causing it to hit the bottom of the big mounting washer. Per attached diagram the top of #14 is hitting the bottom of #6. Stupidly when I put stuff back together I didn't replace the two rubber bushings (#7). If these are worn out would it cause the collar to stick out too far - bushings over compressed or too loose? The collar was centered in between the rubber pieces when I assembled it but has moved somehow over the past few days. Not sure what is supposed to keep it in place, maybe just a tight fit? My plan is to replace both #7's and #10. Does that sound right?

 

That doesn't sound right. I have assembled many front shock assemblies on Hondas before and bever had any issues with play in them. Are you sure you assembled them with he proper torque specs and procedures? Is the mounting nut #16 on tight?

 

Yeah, I torqued everything exactly as shown in Helms. It's worse when it's really cold which also leads me to believe the rubber bushings are toast. They aren't expensive so I guess I will replace them and see if it helps.

 

Replaced the bushings, no more knocking. The old ones were clearly not OE bushings. They were about 1/4" shorter than the new ones allowing collar-washer contact. Now the only noise in the front end is the radius rod bushings. Maybe santa will bring me some new radius rods

 

Good to hear that you were able to eliminate some irritating clunks from the Prelude!

Bushings compress over time and new ones very well could be a good 1/4 thicker than your old used ones. I just went through that with my valve cover seals and I'm sure I'll go through it again when I replace my 100,000 mile suspension this winter. Always replace worn bushings if it's convenient.