Front end Clunk - I'm at a loss

[Brandon96]

Okay, I've got some type of front end clunk ever since I dropped this new engine in. It sounds completely metal on metal, but doesn't 'ping' or 'ding', it's definitely a clunk. It clunks when I'm at full lock left or right and I go over something slightly uneven, for example; turning into my driveway, as soon as my left front wheel meets the end of the driveway its an extremely audible clunk that feels like it's coming from somewhere in the driver's side wheel well. I can feel it in the steering wheel as well as the floorboard. OR if I brake harder than normal, the same clunk occurs in the same location right at the end of the stop, just be for the truck's weight shifts back towards the rear.

I originally thought it was one of my CV's as both sides were doing it. I took them out (placed the stubs in) and got rid of the passenger clunk. This clunk resembles a brutally binding CV, as that's what my passenger side clunk was. Gosh it's been a much smoother ride without those old and busted things!! I then took my shocks off, still clunking. Took the sway bar / links completely off, still there. Replaced the driver's side Hub, a LOT quieter and doesn't make a ratcheting sound anymore, but the clunk is still there. I lowered my torsion twist down about an inch, it's still there. Motor mounts and tranny mounts are still good, or visually appear to be in good shape. I just can't figure out why this thing is still clunking. Also, all ball joints are good, both new to me hubs are good and the truck doesn't pull one way or the other, it's in good alignment.

I heard a lot about the Chevy Torsion bar clunk, where the mounts themselves would begin to loosen from the frame at the rivets. I could see how that would be a problem on the early '95 2nd gens as they were riveted, but mine are bolted and they're all tight.

I'm confused, any ideas?

 

[Sams01XplrSprt]

do u got sound clip of the sound ur talkin bout

 

[MidnightRebel07]

Check the balljoints, passenger side hub bearing tie rod ends. Now that I think about it, make sure you cjeck the rack and pinion setup as well, sometimes after years of wheeling and even normal wear they'll come loose from the cross member where they bolt to and you won't know until it's too late. There's only so many things it could be on these frontends and that's something you didn't mention yet. Hope it's something simple and cheap to repair, let us know what you find.

 

[Brandon96]

I'll try to get a sound clip tomorrow for yah, not guaranteeing anything though as my truck is cammed and has dual flowmasters.. lol

As for balljoints, I know every one of them is good, and I know the outer tie rods are good. Had to replace both lower balljoints, passenger upper and passenger outer tie rod to pass inspection near the end of last year.. I went ahead and did EVERYTHING then. I'll go over all of them again though..

EDIT -- I am suspecting the rack and pinion, or something else regarding the torsion bar... I don't know how and couldn't find how to diagnose and check the different components, or know what I'm looking for for that matter.

I tried my best to get it to clunk while not in motion but I couldn't, not even with getting all 4 tires of the ground and putting it in 4x4.

 

[jd4242]

Sounds like balljoints to me!

 

[dennism3]

The same thing was the stabilizer links on my '97. I had several "checks" over 2 years and finally one guy caught it. Oops you took them off and still there! ??

 

[Brandon96]

Sorry I couldn't come up with a video, BUT, I've narrowed it down to the driver's side frame rail. Coming from the front side of the truck.

It does it whenever I get about 1/8th of a turn from full lock to the left, whenever I hit uneven terrain whilst turning left; for example entering driveways, parking lots making a left up hill etc etc. AND still when I brake hard.

I'm still suspecting something to do with the torsion bar mount, does this sound plausible to anyone? I don't know much about the construction of the mount, couldn't find any diagrams or anything of the sorts. Is there anything within the assembly that could clunk or bang?

 

[Joe Dirt]

Torsion pad? If you feel it under your feet...

When you did the end links, did you replace the sway bar body mounts as well?

 

[Brandon96]

Yes sir, MOOG Part # K80025

It's hard as crap to explain, and the video only picks up my engine noise.. errg. But it's a CLEAR almost metallic clunk, and when it happens, from outside the truck it sounds like the frame rail being struck with a rubber mallet ( exactly like it), from the inside it sounds like it's coming from directly underneath the fire wall, and can be felt in the floor board and steering wheel.

 

[Brandon96]

Ahh, I've found something!

A post back in '05 by Boomin,

there are pads in your 98 but they do not wear out. The 95-97's have the ones with pads I beleive. It is actually a whole tortion key

In this thread here: http://www.explorerforum.com/forums/showthread.php?t=138712

Joe,
While I've got you here, can you elaborate on what was posted in that thread? I see they have diagrams of the '98 and up mounts, but no '95-'97's and from what I understand, they're different and that the '95-'97s have a pad that does wear out? I'm curious now.. lol

 

[kindred4x]

I remember i chased a clunk for months, and checked everything out that you did. I finally found that the upper control arm bolts( cam adjusters) had come loose and was clunking when turning. They are a pain to get to, so im thinking the alignment shop tech didn't torque them down enough when doing the alignment. Must be common because two different shops have done the same thing to my rig.

 

[Brandon96]

Good Idea!... I've got the adjustable cam bolts, I'll give them a check to make sure they're tight. I THINK I torqued them during my quest to get to the bottom of this, but am not sure. I just got an alignment done not too long ago also sooo I'll go out there and check when it's light and not raining out.

 

[kindred4x]

Did you find the problem?

 

[Brandon96]

Nope, still going on I went ahead and got another alignment at my buddy's shop, free to me but I didn't have my truck for a few days.. ergg. So all balljoints/tierod ends and UCA mounts are good.

He briefly looked over things as well but couldn't find anything. The more I look into it the more I think it's a torsion bar mount/pad.. but I don't even know if that's possible yet? hahah Some 2nd gens had different torsion bar mounts/pads than others, I can seem to find out which ones had which.

One other thing I did not look at is the Lower control arm mounts, where they pivot off the cross member. I don't think it's them, but it's just one more possibility i suppose.

 

[gavin]

I have a similar clunk. Pretty much never does it when going straight, only when turning.
I've got a new set of torsion keys I got years ago I'm planning on putting in sooner or later. Need another alignment anyway, last place did a horrible job and didn't even tighten the jam nut on one of the tie-rods. And "not warrantied because it's not stock"

I've had this clunk for well over a year now. The only thing I haven't replaced are the keys.

 

[storlied]

98 is when they improved the pads used for the torsion keys.

 

[Brandon96]

...The only thing I haven't replaced are the keys...

Looks like we're both pre '98, so we should be in the same boat. If you determine what your is please keep me updated! This crap is annoying!

98 is when they improved the pads used for the torsion keys.

Yes I've read they changed to some type of metallic pad for '98 and up? (I could have my facts wrong on that)

But also from what I gather they first changed sometime late '95 / early '96 when they stopped riveting the torsion bar mounts to the frame and began bolting them instead. Now I can't prove that as I haven't see it, but it's what I've been told...

 

[gavin]

Looks like we're both pre '98, so we should be in the same boat. If you determine what your is please keep me updated! This crap is annoying!

oh there's at least 2 or 3 other threads I've posted in with the same issue, and I believe all pre-98. lol.

I'm planning on replacing the keys hopefully within the next month or. Want to go ahead and replace my LCAs and UCAs while I'm at it.

 

[Carguy3J]

Check the front diff-to-frame mounts/bushings. There's 3 altogether one "horizontal" one on each side, and a "vertical" one, on a bracket, on the driver's side. I replaced all 3 on my '99. The passenger side had actually egg'd the frame hole, so I ended up welding in really thick washer, on top of welding up the "bad" part of the hole. Oh, and yeah, the bushings are dealer only. Look at an exploded diagram of the fron diff, you'll see them.

 

[MidnightRebel07]

Check the diff mounts, trans mount and motor mounts as well, you never know.