96 Caravan - New Front End - Still hearing clucking sounds

[jgionet]

Hi all

I just had my entire front end replaced by my brother in law who's a mechanic. (heavy duty mechanic to be exact)

Anyways here's what we switched:
- new rack & pinion (since we tough it leaked when it turned out it wasn't.. a little pi$$3d about that.. but what can you do..)
- new tie rods
- new struts (Monro Sensatracks)
- new strut bearings & plates
- new sway bar bushings and tie ends
- new ball joints
- even the rear shocks were replaced (Monro Sensatracks)

did I leave anything out? (i hope not)
once the work was done I brought it in for a wheel alignement.
(oh and the tires are brand new from last fall)

anyways after all of that I now hear a weird "clucking" noise while hitting specific hard bumps or driving on rough roads. The ride itself is very smooth however this "cluck" or whatever is it is EXTREMELY annnoying and I can almost guaranty it's coming for the struts.. both of them.. but more on the passanger side it seems...

Does anybody have any ideas what this could be? I'd almost have to record the sound so somebody could hear it. (maybe I'll try recording it with a small recorder)
The only thing I can think my bro-in-law "might" have done wrong it install the strut bearings the wrong way. Could that be possible? Can they be installed the wrong way? Would that cause the "clunk" sound? Like I said it runs well.. just until you hit bumps or turn..
I'm baffled/stumped.. any suggestion/recommendations would be greatly apreaciated..

Thanks
-JG

[jgionet]

just something I'd like to add.. do some new shocks normally need a breaking-in period before they run completly smooth? I don't recall ever needing this on other vehicles I've had.

thxs
-MD

[sandokana]

No. Shocks do not need a breaking in period.

“Like I said it runs well.. just until you hit bumps or turn..”
Just a wild guess! Did you check your cv joints?

[caravandrvr]

Yup, since you didn't mention any changing or inspection of CV joints, and since you did mention you hear the clunk when turning, I'd HIGHLY suggest you check your CV joints. The clunk while turning is certainly a KEY indicator for that.

Another big indicator is look under the car and see if the boots covering the CV is either ripped, torn, worn, or has some sort of hole in it. It doesn't take long for those CV joints being exposed to completly toast them.

And no, shocks or struts do not need a 'break in' period.

As for changing the rack when not needed, or perhaps the rest of the front end when your CV joints are the problem:

[jgionet]

thanks for the replies guys.. I'll check out those VC joints when I get home. (once I determine what exactly they are) What's weird though is this "new sound" only started happening once everything was changed. Before I was getting a different type of rattling/clunk sound. I still suspect it might be the Strut Bearing or mounting plate since it only really happens when I hit big enough bumps or a series of bumps/rough roads (which is pretty much everywhere where I live)

I'll report back my findings.

Thanks again

[ElZorro]

What did you find? I am having exactly the same problem with my 2001 T&C. It is sad, the same problem was evident on my previous Caravan which I traded for this one

[Alphabravo]

Try the sway bar bushings. They're known for noises. Good luck.

[Vats]

I have a1999 with the same issue. Replaced the sway bar bushings and sway bar links. Checked the fornt end extensively but can't find anything suspect. Seems to be worst when coing over small bumps, I suspect it may be the drive shaft.

[Bel-air 454]

i had the same problem with my 98 it was a broken sway bar could not tell it was broke until i removed it from the van

[B33p3r]

Same clunking noise on our van. Sway bar links. Picked it up from mech and drove it home and it sounded great. Next day same clunking. The Bolt on the link loosened. Retightened and ok since.