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front end clunking noise

 
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Old 10 Nov 2016, 12:31 pm
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Location: Rochester, Michigan
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Default front end clunking noise

08 base PT 64K miles

clunking noise when driving over uneven or rough pavement
comes from up front, seems louder on passenger side

both lower control arms complete with ball joints replaced @ 30K
both stabilizer bar links replaced @ 42K
both front struts including top bushing replaced @ 52K

lower control arm bushings, tie rod ends, ball joints, stabilizer bar links and bushings, brake caliper/rotor all look/feel OK

nothing obvious but can hear definite metallic clunk, this noise is similar to that when the LCAs were replaced over 30K ago but they appear to be OK

noise has been present for a while, replaced the front struts last year as it sounded like it could be a bad strut... but did not help

any ideas???
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Old 10 Nov 2016, 01:07 pm
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Default Re: front end clunking noise

I doubt this answer is the solution to your problem, but it doesn't hurt to check. I had a similar experience and it turned out to be one of the plastic shields being loose and banging around when I went over bumps or uneven pavement.
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Old 10 Nov 2016, 04:43 pm
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Default Re: front end clunking noise

Check the rear bushing on the right side control arm, the bushing mave have slipped, and I had a ball joint that was pressed into the LCA and was held secure by a outside circlip and it was so loose it started to bang.

Check engine mounts too.
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Old 10 Nov 2016, 06:37 pm
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Default Re: front end clunking noise

Well, spent some quality time under the PT this afternoon pushing, pulling, prying. Found the plastic shield behind the passenger side wheel to be cracked top to bottom but was not the source of the noise. LCA bushings seem OK but did find the passenger side stabilizer bar bushing to have a little play in it. Got a pair of Moog replacement bushings at the parts store but too dark here now to work on it. Will get back on it in a day or two.

Meanwhile, thanks for the replies and will post the results of the bushing replacements.

Last edited by Carl48; 11 Nov 2016 at 10:53 am. Reason: spelling
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Old 10 Nov 2016, 07:17 pm
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Default Re: front end clunking noise

Be sure not to over torque the sway bar bushing bolts and end link nuts. Both torque to 20 ft. lbs. Believe it or not!
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Old 11 Nov 2016, 11:05 am
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Default Re: front end clunking noise

UPDATE
Found the noise source and fixed it !
It was indeed the passenger side stabilizer bar bushing. Replaced both bushings with Moog P/N K80364 bushing kit. This kit fits a 24mm bar which is what mine measured. Amazing to me how such a small amount of play in the bushing (that at first had escaped my notice) caused such a loud annoying noise. btw... thanks for the heads up on the torque specs.
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Old 11 Nov 2016, 02:21 pm
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Default Re: front end clunking noise

Happy to help and happy to hear you solved it relatively cheaply! Happy PT'ing.
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Old 11 Nov 2016, 05:09 pm
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Default Re: front end clunking noise

Glad you found the issue. I had/still have the same noise you're talking about but have yet been able to figure it out..

Changed right side motor mount, 2 new moog strut/spring assembly, 2 new moog complete control arms, sway bar bushings and end links.
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Old 11 Nov 2016, 05:53 pm
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Default Re: front end clunking noise

Are you sure you got the right size sway bar bushings, fox? I had to measure mine to make sure. I have the 24mm bar too.
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Old 12 Nov 2016, 12:24 pm
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Default Re: front end clunking noise

I actually bought all the.. the 22mm 24mm and 26mm ... 24mm matched up exactly as the one on the car
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