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The Telltale Clunk

14126 Views 212 Replies 26 Participants Last post by  VinceBoomBots
Well, I'm at a loss here. I've had this clunk coming from the front passenger side of my 2004 since I bought it. It only occurs at low speed going over bumps and pits, but it's very loud and pronounced when it happens. At this point, I've gone through all the suspension components I can think of and it's still there. I'm thinking maybe it's a motor mount--never heard a bad motor mount make noise like this--or even a wheel bearing--again, never heard of such a thing, but I'm at a loss.

I've replaced:

1. Struts completely

2. Control arms, including all bushings and ball joint

3. Inner and outer tie rods

4. Sway bar bushings and end links

I thought maybe it was the splash guard for the belts, as it doesn't hold together great and kind of flops around, so I both put new pins in it and removed it completely and the clunk persists.

Is there something I'm missing? Could it be a bad CV? The axles seem to be in fine shape, boots are older, but they're not ripped and leaking grease, but they could just be original to the vehicle? I was happy to replace all the parts I did, as they all needed it anyway, but I don't want to throw more parts at the problem and not resolve it at this point.

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That's the great challenge... I've come up with only one contraption that worked for only one set of struts I had and that was to use a socket within a deep well socket that had a "top nut" (similar to a spark plug socket), allowing me to use an extension for the inner socket and a wrench on the outer socket. Next set of struts had different size nuts and I could not find a similar deep well socket for that size... so, that's why I ended up using an impact wrench instead, along with torque limiting extensions.

The impact with torque limiting extensions seemed to work fairly well; however, maybe somebody else here will have a better idea.
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When Re-Torqueing the Top Center Nut on the KYB Quick Stuts...How do you keep the Piston Shaft from Turning?
That's the great challenge... I've come up with only one contraption that worked for only one set of struts I had and that was to use a socket within a deep well socket that had a "top nut" (similar to a spark plug socket), allowing me to use an extension for the inner socket and a wrench on the outer socket. Next set of struts had different size nuts and I could not find a similar deep well socket for that size... so, that's why I ended up using an impact wrench instead, along with torque limiting extensions.

The impact with torque limiting extensions seemed to work fairly well; however, maybe somebody else here will have a better idea.
That's the great challenge... I've come up with only one contraption that worked for only one set of struts I had and that was to use a socket within a deep well socket that had a "top nut" (similar to a spark plug socket), allowing me to use an extension for the inner socket and a wrench on the outer socket. Next set of struts had different size nuts and I could not find a similar deep well socket for that size... so, that's why I ended up using an impact wrench instead, along with torque limiting extensions.

The impact with torque limiting extensions seemed to work fairly well; however, maybe somebody else here will have a better idea.
Well, ****'s Bells Martha...I Already got the Wiper Tray Out...Sooo I'ma Gonna Gets a LARGE Pair of da Vica Grips.. Clamp Down on that there Shiny piece of Metal ina between the Springs and go back top an Crank Down on Mr. Struts...Nuts...B.T.W. What is the Torque Setting ???
Thx😎
Per the 2005 service manual, "strut shaft nut" specification is 75 ft-lbs (100 N-M). Let us know how it goes!

Apparently we are supposed to use something like this:


Don't know the nut size off-hand though...

OEM tool is Strut Rod Nut Wrench 6864!

Here's one on ebay (May not match KYB Nut though...):

MILLER TOOL 6864 STRUT NUT WRENCH | eBay
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Per the 2005 service manual, "strut shaft nut" specification is 75 ft-lbs (100 N-M). Let us know how it goes!

Apparently we are supposed to use something like this:


Don't know the nut size off-hand though...

OEM tool is Strut Rod Nut Wrench 6864!

Here's one on ebay (May not match KYB Nut though...):

MILLER TOOL 6864 STRUT NUT WRENCH | eBay
Almost looks like an 02 Sensor Socket
Per the 2005 service manual, "strut shaft nut" specification is 75 ft-lbs (100 N-M). Let us know how it goes!

Apparently we are supposed to use something like this:


Don't know the nut size off-hand though...

OEM tool is Strut Rod Nut Wrench 6864!

Here's one on ebay (May not match KYB Nut though...):

MILLER TOOL 6864 STRUT NUT WRENCH | eBay
Can't find My 'LARGE' Vice Grips🤔
Can't find My 'LARGE' Vice Grips🤔
I hope you are kidding about using Vise Grips, that will likely damage the rod and cause the strut to leak.
I hope you are kidding about using Vise Grips, that will likely damage the rod and cause the strut to leak.
Just Kidding....BUT if I get that Frustrated...I gots me Plenty of Fluid Film and Wool Wax...
Almost looks like an 02 Sensor Socket
I tried O2 sockets, but the slot allows the socket to spread and slip on the nut. Needs to be a solid deep well socket that allows you to get a socket extension down the middle for a smaller socket insdie to hold the rod while you turn the outer socket. More like a spark plug socket...
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When Re-Torqueing the Top Center Nut on the KYB Quick Stuts...How do you keep the Piston Shaft from Turning?
use an allen wrench with a strut nus socket,
such as this:
Nickel Jewellery Household hardware Automotive lighting Font

or miller special tool already mentioned
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I tried O2 sockets, but the slot allows the socket to spread and slip on the nut. Needs to be a solid deep well socket that allows you to get a socket extension down the middle for a smaller socket insdie to hold the rod while you turn the outer socket. More like a spark plug socket...
Thank you...Now I get it...An Expensive But Necessary Tool
use an allen wrench with a strut nus socket,
such as this:
View attachment 70317
or miller special tool already mentioned
Thx
Bang for the buck, a kit like this MIGHT be the answer:



Or this one that looks like it MIGHT be a little better quality:

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Bang for the buck, a kit like this MIGHT be the answer:



Or this one that looks like it MIGHT be a little better quality:

Thank You...This is Just what the Doctor Ordered...Thx Again...
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