Guys,

I thought I found that the sway bar bushings were causing my front end passenger clunk and popping but guess what, they weren't.

Before I drop the bomb and show what I learned through scouring the internet, I have replaced the following:

Lower Ball Joints
Passenger Upper Ball Joint
Sway Bar End Links (Had to be replaced Anyways)
Sway Bar Bushings
Front and Rear Shocks

Total bill: ~US$600

After all of that, it wasn't even the problem. There is a service bulletin that talk about this in this upcoming video.

Want to know what the clunk is? Here you go!

http://www.tweaknews.net/decarbon/one.JPG

Remove this 7mm screw holding the small outer cowl inserts over the hinges. Close the hood.

Remove the covers carefully and don't break the clips.

The hingles will be attached and they are a 13mm nut and bolt.


97PUO-BDM0o

That's right, a $2 dollar part fixes this problem that has pissed so many Blazer owners off.

This is the service bulletin that came out in 2001 I believe. Covers all S10 and Blazers.
Hood hinge clunk fix
TSB 01-08-63-001A
GM part # 12383460
This bulletin is being revised to add model years. Please discard Corporate
Bulletin Number 01-08-63-001A (Section 08 -- Body and Accessories).
Condition:
Some customers may comment on a rattle coming from either or both front
corners of the instrument panel near the hood hinge areas. This noise may
often be mistaken for a loose shock absorber. The rattle may be heard when
driving over rough roads and is most noticeable when the road surface
creates a side-to-side vehicle motion.

Cause:
Excessive clearance at the hood hinge attaching bolt may cause this
condition. The excessive clearance allows the hood hinge to make metal
contact with the hood hinge bracket, which produces a rattling noise.

Correction:
Important: For additional information, see the Body Front End subsection of
the Body and Accessories Section of the appropriate Service Manual.

1.. Remove the hood hinge attaching bolt (1).
2.. Install a spring washer (2) on the bolt as shown in above
illustration.
3.. Install the bolt.
Tighten
Tighten the bolt to 25 N·m (18 lb ft).

Parts Information
Part Number: 12383460

Description: Washer - Hood Hinge

© Copyright General Motors Corporation. All Rights Reserved. There you have it, I temporarily laid a couple bunched up shop towels under the flat part in the video and went for a drive on the roughest washboard road within 50 miles and never heard a thing.

Hope you don't go through what I went through.

http://img.photobucket.com/albums/v448/therealsundance/DSC00309.jpg

http://img.photobucket.com/albums/v448/therealsundance/DSC00310.jpg

http://img.photobucket.com/albums/v448/therealsundance/DSC00311.jpg

http://img.photobucket.com/albums/v448/therealsundance/DSC00312.jpg

OMG
I remember doing a bunch of thoes with that first came out.
We where going NUTS trying to find the front end noise.
The washer looks like a wavy spring washer.
AND IT WORKS.
No one it the shop could belive that a washer could fix that noise but it does.
Fireplug

Yip, the waser is like a cone and I installed it 30 minutes ago and the knock that has plagued my truck and my wallet is completely gone for good.

I am absolutely so happy and just had to share this with everyone.

I was just about to replace the ball joints in my wife's 97 Jimmy till I ran across your post. And quess what? Sure enough, it was that hinge bolt. Thanks for taking the time to post the advise! Sure saved me alotta $$ I can't afford & not to mention the aggravation.

Thanks Again,
Gene

You are really welcome!! :D

I am very happy that I saved you money. I hate for people to go through what I have.

Please send me more information, the links were not valid.

This thread has been dead for over 6 years, that's probably why the links don't work. The washer kit is available at any GM dealer, it comes with instructions, and cost is about $8 per side. All you need is a 13mm wrench and 10 minutes time.

Hood hinge clunk fix
TSB 01-08-63-001A
GM part # 12383460
This bulletin is being revised to add model years. Please discard Corporate
Bulletin Number 01-08-63-001A (Section 08 -- Body and Accessories).
Condition:
Some customers may comment on a rattle coming from either or both front
corners of the instrument panel near the hood hinge areas. This noise may
often be mistaken for a loose shock absorber. The rattle may be heard when
driving over rough roads and is most noticeable when the road surface
creates a side-to-side vehicle motion.

Cause:
Excessive clearance at the hood hinge attaching bolt may cause this
condition. The excessive clearance allows the hood hinge to make metal
contact with the hood hinge bracket, which produces a rattling noise.

Correction:
Important: For additional information, see the Body Front End subsection of
the Body and Accessories Section of the appropriate Service Manual.

1.. Remove the hood hinge attaching bolt (1).
2.. Install a spring washer (2) on the bolt as shown in above
illustration.
3.. Install the bolt.
Tighten
Tighten the bolt to 25 N·m (18 lb ft).

Parts Information
Part Number: 12383460

Description: Washer - Hood Hinge

© Copyright General Motors Corporation. All Rights Reserved.

Please send me more information, the links were not valid.
I've added the video and some pics to the first post, along with the TSB info that OM provided. Hopefully you will find it more useful now. If you still have questions, feel free to ask. Otherwise, let us know if this fixes your problem. :thumbsup: