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01 S, 04 XT, 14 XT
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245 Posts
Discussion Starter #1
Yay another diagnose my clunk over the internet thread! New to me '14 XT, 85k miles.

Odd clunking noise in front end, primarily passenger's side. Sounds like loose top nut, seems to be primarily over small, repetitive bumps like rumble strips at low to medium speeds. I get the impression noise occurs at suspension extension but can't be sure. Gravel roads sounds like front end is totally blown out and flopping around. Somewhat irregular occurrence but can reproduce. I can slightly feel it through steering wheel. No play in wheels at 3&9 or 12&6 when lifted and wiggling.

New control arm assemblies both sides (including ball joints) - both frame and subframe mount bushings were badly worn

New swaybar bushings - both were worn

New endlinks - both seemed fine

New struts - both seemed fine

New coil insulators - both were worn through where coil ends

New top hats - one bearing seemed slightly rough (drivers) but no detectable play or bushing wear either side

I don't see any wear / play in motor or transmission mount. No play steering rack that I can see. No sign of rubbing etc on any components that I see. Everything I can get a wrench on feels tight.

Alignment tech could only get caster within .1deg of caster spec on passenger side (where noise seems to be worst) if that means anything.

I'm at a loss! Waaaaay too much time $pent trying to track this down with no love! Someone please tell me what I'm missing here?
 

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Registered
01 S, 04 XT, 14 XT
Joined
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245 Posts
Discussion Starter #2
Update on this, the cause of the noise was passenger CV axle. Axle felt fine and performed perfectly but outboard boot started to sling grease so I removed boot to replace and realized from the internals that it was a non-OEM axle that must have been replaced by previous owner. Looked OEM externally but different CV design internally, perhaps a refurbished piece? Replaced axle and noise stopped.
 
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