2000 T&C awd clunk noise

[lukedwag]

Ive got a T&C with a noise that seems to be in the front end. 134k miles 3.8l awd. Happens slightly noticible over bumps at higher speeds but is more apprent at low speeds in bumpy driveways. Its got new outer tierods, just put a new rack it cause I found there was some perpendicular play in the rack bushings. sway bar links seem to be tight as do the ball joints ..... springs are intact and struts show no sign of leaking. I am lost and getting discouraged lol. any ideas ? It seems to to creatable by kind of swerving side to side on the road....... I got not somebody throw me some ideas

[KManiac]

If you haven't done so already, please search this forum for my various posts regarding the AWD system in these vans. You should be able to find a recent post called "another awd" last updated on March 6th, which covers this in greater detail.

Here's the bottom line. You are experiencing the simultaneous loss of traction with both front tires. This can happen easily on ice, gravel, uneven and unstable surfaces. When this occurs, full drive power is suddenly and immediately redirected to the rear wheels by the Power Transfer Unit (PTU). The sudden engagement of the clutches in the PTU causes a clunking noise and feels similar to popping the clutch in a stick shift car. This clunk in NOT an indication of worn parts or impending failure. It is simply the AWD system responding as designed to this specific condition and lets you know the system is working correctly.

My wife drove me nuts for seven years with her complaints about this mysterious clunk until I finally figured out how the system worked. And everyone I know who owns an AWD van has experienced this condition more than once and the dealer mechanics are clueless about this condition.

Let us know if you have any other questions or comments.

[lukedwag]

Originally Posted by KManiac

If you haven't done so already, please search this forum for my various posts regarding the AWD system in these vans. You should be able to find a recent post called "another awd" last updated on March 6th, which covers this in greater detail.

Here's the bottom line. You are experiencing the simultaneous loss of traction with both front tires. This can happen easily on ice, gravel, uneven and unstable surfaces. When this occurs, full drive power is suddenly and immediately redirected to the rear wheels by the Power Transfer Unit (PTU). The sudden engagement of the clutches in the PTU causes a clunking noise and feels similar to popping the clutch in a stick shift car. This clunk in NOT an indication of worn parts or impending failure. It is simply the AWD system responding as designed to this specific condition and lets you know the system is working correctly.

My wife drove me nuts for seven years with her complaints about this mysterious clunk until I finally figured out how the system worked. And everyone I know who owns an AWD van has experienced this condition more than once and the dealer mechanics are clueless about this condition.

Let us know if you have any other questions or comments.

I dont think that this noise is from the AWD system. I do have the common clunk while backing up. If I grab the passenger side wheel and rock it back and forth as hard as I can I get the thud that sounds like a balljoint is out but I cant get the noise or any movement when its off the ground. I think I need a halper to rock the wheel while I look around for signs of noise and movement.

[xj31]

You said the sway bar links are tight but how about the bushings?

[lukedwag]

Originally Posted by xj31

You said the sway bar links are tight but how about the bushings?

They seem to be ok, maybe I should just change em ... is that common ? the bar does sit pretty close to the subframe so I supose with some up and down movement to it it might be hitting the frame.

[xj31]

Its very common,I was surprised no one else brought it up.It sometimes sounds like something is hitting the floor,especially over small bumps.They're cheap too