I have 04 and 07 aveos both with the dreaded strut gaps. With much searching I think I have solved the problem or at least have a workaround without new bushings.

It looks like the top bushing has been universally installed upside down. I have attached an exploded parts diagram of strut which clearly shows the bushing oriented with the bevel down.

It is quite natural to want to place the bevel up so that it fits neatly into the frame metal of the same shape. But oriented as such there is a large gap with play of 1/2" no matter whether or not the bushing is new.

Flipped beveled side down as shown in the second attachment, you can now torque to spec (44 ft-lbs) and drives greata ENDS THE KNOCKING AND OTHER RATTLES. Both my Aveos are smooth and cushioned. Name: 373CANON.jpg Views: 28524 Size: 240.3 KB