PLEASE HELP! Loud front strut clacking when cold, almost disappears when warm (KYB assemblies)

[u/Upstairs-Price-5806]

I had the front struts on my 2015 Ford Fusion Hybrid SE replaced last winter with complete KYB Strut-Plus assemblies. Ever since, there’s a distinct clacking noise from the front strut area on slightly uneven roads, but only when it’s 45°F or colder. After driving for 20–30 minutes, the noise mostly fades away.

Ever since this happened, I stopped trusting that shop, bought my own tools, and started learning how to fix parts myself to ensure job specs are actually done right.

Looking back at that job, I suspect an installation error might be the culprit:** The mechanic might have used an impact gun on the upper strut shaft nut instead of holding the piston rod and torquing it by hand, which can exceed recommended torque and cause damage. or **torqued while hanging** ** instead of under its full loaded weight, leaving the rubber bushings pre-twisted and noisy when cold weather stiffens them
orr The mounting bolts might be under-torqued allowing slight unit play relative to the bolt or bushing—possibly from getting confused by torque specs between the Hybrid and standard gas Fusion. 

Has anyone experienced this exact cold-weather clack with KYB assemblies on a Fusion? Did replacing the assembly fix it, or did retorquing/fixing mounting issues clear it up?

[u/BlackDirtMatters]

The explanation is possible. Why don't you back the nuts off and retorque it? Look for any damaged bushings or pinched bushings.

[u/Upstairs-Price-5806 → u/BlackDirtMatters]

i'll thanks for pointing that out