Manning

So I get this clunking in the front end on my car. It only happens when I am either going around a tight corner, usually at slower speeds (maybe can only hear it then) or when I first start to pull up an incline, like a driveway.

This is starting to **** me off as I have replaced just about everything in the front end and the noise just won't go away <img src="graemlins/crying.gif" border="0" alt="[crying]" />

So, here is what I have replaced:

Complete tie rods, both sides
Ball joints, both sides
Upper strut mounts, both sides
Koni yellow cartridges are fairly new and not loose at all.
Motor mounts (after market) are under 6 months old
Wheel bearings, complete, both sides

So, could worn out A-arm bushing cause this? Could the stupid Weltmeister bar I have on the front cause this clunking? I did notice that the lower mounts for the sway bar look like the link may contact it at times, but I would think that would be during really hard cornering. Also, it isn't the same sound as when the sway bar smacks into the tray under the car. The current noise is more of a clunk than a clank.

Tabor

I know that worn out stock sway bar bushings are known to cause this. Also, I assume that worn out a-arm bushings could. I think Zimms will replace the bushings for $50 per side.

Are you shure it is comming from the front? Might it be from CV joints in the back and it just sounds like the front?

Good luck, on my car it was the ball joints, but you already replaced them.

Ken

Do me a huge favor. Check the upper strut mounting bolts for tightness. You know, the 22mm ones under the hood. I did the complete rebuild and i had the same problem. I let it go too long without finding it, the nut fell off and ending up ruining one of my new Koni inserts. PLEASE don't drive it without checking these. I'd hate to see someone repeat my mistake. Good luck!

Manning

Well, the center sway bar bushings are fairly new also, I just forgot to list that. They looked really crusty and trashed out, so I got a set from Jason. You think maybe the little clamps that keep the bar centered (they ride against the center bushings) could make a clunking noise against something when the bar twists?

I am 100% sure it is coming from the front end. It seems like something cocking when I turn a corner or right as I hit a transition onto a driveway. Also, I know the CV noise pretty well as I had to take care of that close to a year ago on this car, and have had to deal with it on all the front drivers I have owned or used.

All of the cross member bolts are torqued correctly as are all of the suspensions nuts/bolts.

Manning

Good idea Ken. That was the first thing I thought of. They are both plenty tight.

Joel

Did you check to see if the front swaybar is actually bolted down? On my car one side of the swaybar came loose somehow, dropped down and proceeded to take out one of the steering rack boots. It's a good thing we fixed that before getting on the track!

The clunk has to either be a swaybar or shock mount, I would think. CV joints usually click, not clunk.

Hans

[quote] So, here is what I have replaced:
...
Wheel bearings, complete, both sides <hr></blockquote>
Front wheel bearings might require re-ajustment some time after installation.
Outer race might require some time to set itself, depending on the method of installation (punch/hammer versus hydraulic press)
You might also want to check the brake calipers (fasteners as well as easy movement of the pads), especially with the floating piston type
TakeCare

Michael Stephenson

I had a similar problem that turned out to be a cracked sway bar drop-link, one of the ones by the A-arm.

Also, I got a little bit of a clunking sound when the nut for the A-arm by the eccentric was loose. Totally my fault for not torqueing it properly when I had my A-arms rebuilt.

Matt

I'd suggest disconnecting both swaybar droplinks, either at the bar or control arm end. Tie or tape them up out of the way, and drive the car. This will take the swaybar out of the equation and tell you the bar is or is not the culprit. The Welt bars can be somewhat noisy, though it's my rear one that has always clunked.

Matt

Doug944s2

I had Michael's problem...I thought I had torqued down the nut on the caster eccentric succifiently but it came loose. Made a clunking sound over speed bumps and on initial brake application.

Be persistent...you'll find the source!

Manning

but I don't want to be persistant I want someone else to find all the answers for me <img src="graemlins/crying.gif" border="0" alt="[crying]" />

Just kidding.

I guess I am going to have to go through and check all the bolts and such again. I just check the wheel bearing this weekend, so I think (hope?) I can rule those out. I may try Matt's idea about disconnecting the drop links. I think in the long run I may as well replace the A-arms and A-arm bushings since they are original to the car. They don't look too fried, but I am sure they have seen better days.

Regarding Michael's comment, do you think the swaybar end of the drop link (the end with the rubber insert) can get worn out bag enough to make noise?

I think I may have to get rid of the Welt and come up with a 968 M030 to sneak on there somehow.

Manning

Alright, I am not 100% sure this was the problem but I had no clunking on the way to work today so it may have been.

Anyway, I went home last night and went over the car top to bottom. Check every suspension bolt and the wheel bearings. All checked out fine. So while I am looking under the car I notice the *new* bushings on my sway bar look kind of distorted. Not like they have squished or anything (which would be pretty tough anyway since they feel like hard plastic, not rubber or poly), but the hole on the outer side seems kind of wallowed out. Hmmm.

I really didn't want to have to unbolt the bracket and pull out the bushing to re-grease (yes I had greased them with Teflon paste when I installed them) the bar and bushings. Instead I whipped out a can of motorcycle chain wax spray and soaked 'em down.

And the result has been no clunking so far. WTF? I have driven cars with poly bushings in the past and have NEVER heard any of them make a sound like this. It was a hard *clunk* not a creak or squeak and really sounded like something was knocking around. Very weird.

billybones

sounds like the sway bar has lateral movement. That is equal to arm movement. pulling the bar through the bushing under duress such as extreme turning or changing the plane of movement..

MSwain

Manning-

I have the exact same thin happing on my 88 924S with 030. I jacked up the front end and moved the wheels from left to right to full lock in both directions. The clunk came from the spring sliping on the top perch. There seems to be a goove in there that it snaps back and forth on. I'm still not sure what cuases it, maybe the bearing at the top of the strut is a bit too tight? If the clunk comes back check this out also.

-Mike

Manning

Yeah, that's exactly what it sounded like, like the spring was getting cocked and then popping back. Lock-to-lock the upper bearing move fine though.

I'm keeping my fingers crossed that I have it located.

Thanks for all the helpful input.