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Front End Clunking

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Bwildered1

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Discussion starter · #1 ·
Earlier this year my '04 Durango developed a clunking noise in the front end, usually turning left at 30-50 mph and hitting a small bump. It also happens on a smaller scale when driving across rough ground, and sometimes when I first start to back up. At times it's severe enough that my front seat passenger can feel it though the floor. I don't feel anything through the steering wheel.
Here's what I've found in order:
1. Lower ball joints visibly worn. Replaced them and the clunk remains.
2. Upper ball joints- replaced ball joint/control arm assemblies. Clunk remains.
3. Sway bar links/bushings. No perceptible wear but the links felt a little loose so they were replaced. Clunk remains.
4. Took most of the lash out of the steering rack. Clunk remains.
5. Replaced inner and outer tie rod ends. Inner rod ends moved freely but had no perceptible wear. Outer rod ends still tight. Clunk remains.
6. I don't see any wear or damage to the lower control arm bushings.
7. I have new bushings/pins for the brake calipers that I'll put in this weekend, but I don't expect that to fix the clunk. I'm only changing them because the driver's side bushings feel a little looser than the passenger side.
8. Both front axle CV shafts are nice and tight. Wheel bearings are nice and tight.

I'm open to suggestions. Anyone else encountered this? Thanks for any input!
 
#2 ·
Motor mounts and tranny mount. How many miles are on it? If you have a transfer case it could be in there.
 
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#7 · (Edited)
How about the bushings in the cross member where the torsion bar keys fit? I have yet to see some that aren't shagged, and they were causing a lot of clunking noises in mine before I replaced them with polyurethane.

You have to drop the crossmember and get a lever inside them to really see the extent of the deterioration. I wrote a thread about it. It is an easy job.

Did changing the bushings and pins on the brakes help anything?

Are they really bushings, or just dust boots?

The bushings in the lower control arms are good, right? You have to pull them out too to really see. And the chassis bolts are tight, right? There is no movement in any of them?

I noticed with mine that when I had the old engine mounts and transmission mount in there, when I braked and took off the engine and transmission had some movement, I was getting clunking from the yoke (transmission end of tailshaft). You can lever that steel plate just in front of the transmission tailhousing extension against the chassis to see. Anyone else had that? I wondered if the yoke was worn.

Anyway, I am keen to see what it is, so keep us updated, please.
 
#10 ·
wannaeatyourbrains said:
Yeah right. That is interesting. I just changed the pads and clips in mine, and they still have a little noise if I brake hard. That is why I was asking about aforementioned pins. What causes it? Any way to fix it?
Click to expand...
So when i bought my Ram i actually sent it back to the dealer for that clunking. They changed Pads 2 different times and i still get the clunking/crackling noise. They just told me it is a characteristic of the caliper design.
 
#11 ·
Yeah right that is interesting. A clunking crackling noise is spot on. Mine are mechanically A1 and to spec, so I was a little bewildered. It is good information. Thanks.

RAM is a fine car, by the way. Would that I could own one. Foreigners are forbidden utes here, so alas, it is never to be. I would love one with the Cummins motor. Finest automobile ever made, I reckon. I don't know why average Americans aren't more supportive of American manufacturing, cause you make great stuff.
 
#12 ·
wannaeatyourbrains said:
Yeah right that is interesting. A clunking crackling noise is spot on. Mine are mechanically A1 and to spec, so I was a little bewildered. It is good information. Thanks.

RAM is a fine car, by the way. Would that I could own one. Foreigners are forbidden utes here, so alas, it is never to be. I would love one with the Cummins motor. Finest automobile ever made, I reckon. I don't know why average Americans aren't more supportive of American manufacturing, cause you make great stuff.
Click to expand...
Absurd amount of taxes and regulations scare American manufacturing away unfortunately
 
#13 ·
Yes I am dealing with the same issue now I’ve replaced everything from lower control arm to upper the springs the struts the seat bar links tie rods are good only thing I didn’t get was a new rubber boot that was suggested so we will see mine only happens when going less the 30 mph when I hit a bump or make a left or right turn
 
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