[Carbuff2]

Are you positive that the sway bar end links are tight? A bit of looseness can result in a CLUNK but would be difficult to diagnose (unless you disconnected both sides for a test drive). They can be difficult to tighten fully. (which is why I like the MOOG brand links, they have a proper hex on the inner side)

Did you replace the upper strut mount bearings?

Are you positive the noise is coming from the front and not the rear?

I've never heard of a bad CV causing a clunk as you describe.

 

[Carbuff2]

Poly bushings don't twist like rubber. That is why they require lubrication. The bar rotates inside poly bushings, instead of twisting.

The minivan's retainer brackets for the sway bar bushings have a tang and only one bolt. Last time I changed mine I added rubber (inner tube material) between the bushing and bracket to tighten them up, I think I re-formed (AKA bent) the tangs as well.

 

[Carbuff2]

OK friends, TOPIC DRIFT ALERT!

Be nice to one another. Lets just help the OP with the issue.

 

[Carbuff2]

I fixed my noises, and well that is all I'm going to say on the matter.

Or, just tell your passengers:

"Those noises tell me that the suspension is working" LOL

 

[Carbuff2]

I'm in the 'torsion bar' camp of intended design.They SHOULD grip the sway bar tightly (as the control arm bushings do).

I've had noises from dry/slipping sway bar bushings on other makes' cars, but never as often as on our '02 van. (And we have an advantage, the 'touring suspension' has bigger sway bars)

The third time I replaced the sway bar bushings, I think I glued the bar to the bushings.

I also roughed-up the interface area of the metal bar by gouging them with 'toothy' vice-grips. And as previously stated, I tightened the tab away from the single attaching bolt and provided more tension with a layer of inner tube rubber inside the bracket.

Last replacement was almost almost 7 years ago, 48K miles, with MOOG bushings, according to my records. No noises to date.

 

[Carbuff2]

PS: Did Carbuff2 use gorilla glue between his sway bar and bushing, or what?

JB Weld. I use that s**t for EVERYTHING. 😇 Seems like it, anyway.
Yes, my fix is patented. Just warning you...

(Though, I COULD have used Krazy Glue...did I ever tell you I have a bad memory?)

 

[Carbuff2]

Seems reasonable. But then the question becomes what do you do with caked on JB Weld on the sway bar in the event the bushing still goes?

I was only kidding about the JB Weld for Jeepman's benefit.

But think about this: any lumpy caked-on JBW will grab the replacement bushing better than a smooth bar, the next time you renew them ...

 

[Carbuff2]

Just think, we have sent humans to the moon

To get away from their clunking minivans??? Can't hear it from there...