How to remedy an occassional "Clunk" with raised suspension

Some useful articles on doing it yourself
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How to remedy an occassional "Clunk" with raised suspension

Post by Family_Dog »

Bulldog made the occasional grating sound of metal bashing metal when I drove on uneven ground, even over a mild depression on a tar road. The cause of the problem was that the local agents (not Menlyn!), when fitting the OME suspension, did not fit the front driver-side U-bolts correctly, with the result that part of the steering arm caught against the U-bolt when underway.

The solution, provided by Warthog 4x4 Spares here in Klerksdorp, was to simply swap the two U-Bolts around. You will note that one of the U-Bolts has a flattened section at the top to prevent this happening by providing extra clearance. Problem solved!


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Re: How to remedy an occassional "Clunk" with raised suspension

Post by Cookie Monster »

HI Eric

You got a pic of that I have the same problem :(
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Re: How to remedy an occassional "Clunk" with raised suspension

Post by Family_Dog »

Will try and take a pic over the w/e. But have a look, the U-bolt with the flattened portion is easy to see.

TIP: Jack the body up and remove the front right wheel. Lower the front axle onto a tripod so that it has weight on it before you loosen the U-Bolts.


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Re: How to remedy an occassional "Clunk" with raised suspension

Post by Umvubu »

Had the same problem with my 4y ironman suspension. Removed one blade from each of the front leafsprings. No more steering getting caught. :D
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Re: How to remedy an occassional "Clunk" with raised suspension

Post by Dadz Toy BFI »

C'mon Uncle Eric


THIS THREAD IS NO GOOD WITHOUT PHOTOS :shock: :shock: :shock:

You know the Protocal by now.................. :wink:

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Re: How to remedy an occassional "Clunk" with raised suspension

Post by Family_Dog »

Geez, but these Capies can nag! :mrgreen:


I actually did take some photos and then forgot to upload them.
Steering Rod and U Bolts 001 Resize.jpg

Steering Rod and U Bolts 003 resize.jpg

If you look carefully at the U-Bolt furthest away, you will note that it is slightly flattened at the top part of the bend, compared to the closer U-bolt, which is round. This is very easy to see when you look at the actual U-bolts. The local OME fitters had this the wrong way round, with the result that the steering knuckle (grease-covered above) would clang against the rounded U-bolt when driving on an uneven surface. Since reversing the order of the U-bolts, this has never happened again.


-F_D
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Re: How to remedy an occassional "Clunk" with raised suspension

Post by Dadz Toy BFI »

KNEW YOU COULD DO IT ERIC :D :D :D :D

Cheers

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Re: How to remedy an occassional "Clunk" with raised suspension

Post by JohanM »

Thanks Uncle Eric for the informative tip on the suspension. :lol:

Is that a diff breather extension pipe that I have seen on the front diff off Bull dog??? :wink:
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Re: How to remedy an occassional "Clunk" with raised suspension

Post by Family_Dog »

Yep, nothing fancy, it just goes to the engine bay and is fastened to the brake master cylinder with a cable tie. It ends in a petrol filter, which has the added advantage that I always have a spare petrol filter now if I ever need one :)


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Re: How to remedy an occassional "Clunk" with raised suspension

Post by Scorpion »

Family_BullDog wrote:Yep, nothing fancy, it just goes to the engine bay and is fastened to the brake master cylinder with a cable tie. It ends in a petrol filter, which has the added advantage that I always have a spare petrol filter now if I ever need one :)


-F_D
I also just had Blom's breather fitted (check it out at Rebel4x4.co.za). Post us a pic of the petrol filter up top, oom Eric, please!!!! :mrgreen:
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Re: How to remedy an occassional "Clunk" with raised suspension

Post by optirite »

I have the same 'clunk' but not with a SFA. My Hilux is a 2000 model. Any ideas???
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Re: How to remedy an occassional "Clunk" with raised suspension

Post by optirite »

Well, that was on a SFA. I have a IFS model, that van Zyl springs have added a blade to the back. They also turned up the torsion bar setting on the front, yet even the smallest of bumps results in a knocking from the front suspension. It is feelable through the floorboads as well. Any ideas???
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Re: How to remedy an occassional "Clunk" with raised suspension

Post by LouisZ »

Your Torsion bars are set too far(too high). Get under the IFS, check the to bump stop, there should be a gap of about +/-12mm.
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Re: How to remedy an occassional "Clunk" with raised suspension

Post by optirite »

Thanks, I checked this morning and the gap is about 30mm. So you reckon that I need to turn this back down.....? The hight of the bottom lip of the fender is 84cms at the moment. The rear stands a bit higher than that. My fear if I turn it down is that the tyres will catch. I am running Broncos (same as 265 Muds). Any advice please.

Many thanks.
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Re: How to remedy an occassional "Clunk" with raised suspension

Post by dalkill »

lately I have been noticing some rattles and clunks when driving on badly corrugated dirt roads.
on tar I hear nothing. How can one find the source of the noises without having to hang onto the chassis while driving a dirt road :mrgreen:
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Re: How to remedy an occassional "Clunk" with raised suspension

Post by Zandyl »

How can one find the source of the noises without having to hang onto the chassis while driving a dirt road :mrgreen:
Get somebody else to do it
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Re: How to remedy an occassional "Clunk" with raised suspension

Post by dalkill »

Zandyl wrote:
How can one find the source of the noises without having to hang onto the chassis while driving a dirt road :mrgreen:
Get somebody else to do it
thanks for volunteering Jaco :thumbup:
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Re: How to remedy an occassional "Clunk" with raised suspension

Post by optirite »

Found the problem. To give feedback...
Workshop1 came back to me and said that the chassis was bent! Would need a chassis puller to fix.
Workshop 2 (Suspension specialist) came back and explained that the suspension was repairable at between 16 and 18 thousand rand.

I knew that workshop 1 was talking nonsence as I do panel beating and I have yet to see a Hilux chassis get bent in that way. I also did not have between 16 and 18 thousand rand to give to some so called specialist as well. I put the Hilux up on a lift and noticed that the right front lower ball joint cap was torn open. Hmmm in the lifesime of a Hilux I suppose that you could classify ball joints as a consumable item on a suspension. R 650 later I had four new ball joints, installed them and hay presto. Problem solved!!! A further
R 200 to do alignment, after resetting the hight and I am home rattle free. :thumbup: :thumbup: :thumbup:

(Funny enough en route home I heard a rattle from the front left side, but it turned out to be a d-shackle that was rattling on one of the recovery hooks.)
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Re: How to remedy an occassional "Clunk" with raised suspension

Post by Family_Dog »

Well done, Mike!


You can throw one helluva party with the $$$ that you saved, and still pocket some! :mrgreen: :mrgreen:


-F_D
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Re: How to remedy an occassional "Clunk" with raised suspension

Post by Mud Dog »

My SFA has had such a clunk ever since I got it, but usually only when turning, and one also feels it in the "floor boards". Of course an SFA does'nt have ball joints and it was still there after fitting OME so I ruled out the suspension. The u-bolts are the right way around, not that either, I even thught it may be something with the steering box / pitman arm but then I would feel it in the steering. No play in the steering arms, so it's not that either. Neither is it loose calipers. That only leaves the axle ifself, and I wondered if the half shafts were 'floatng' a little (if that's at all possible) and clunking as they slid from one side to the other with centrifugal force in a turn. It's never been a problem as such, just an occasional reminder that something ain't 100's. So many SFA owners exprience these 'clunks' that I almost consider it to be 'normal'.
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Re: How to remedy an occassional "Clunk" with raised suspension

Post by Family_Dog »

Before Bulldog received the OME suspension, he also "clunked" when I turned, but only when on an incline. We found the reason why when replacing the suspension - the left front shock had snapped clean off and was obviously having no effect anywhere with damping. The steel rod had snapped off - how does this happen?


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Re: How to remedy an occassional "Clunk" with raised suspension

Post by Mud Dog »

The steel rod had snapped off - how does this happen?
:shock: :shock:

This is not the origin of my 'clunking' and until recently I had never heard of this problem, yours being the 2nd incident I've ever known. To be honest, since my late teens when I got my first car, I used to wonder how the stanchions in shocks were able to survive. In retrospect I reasoned that the forces were linear and not lateral and that the 12 to 14 mm thick steel rods were adequate. At the same time I realised that the critical stress point was the threaded end tip where it's secured to the body. That stress is magnified if the bolts are'nt tight and there is some play, producing a type of hammering. Many years ago I fitted a set of Bilstein's to my 7 series BM and was impressed with the 20mm stanchions (the thickest I've ever seen) but still thought it to be 'overkill'. I can only imagine that perhaps these days there are more a more corners being cut in production leading to poorer quality, and with 'built in obsolescence' as well, the old adage that 'nothing lasts forever' is not only re-inforced, but being emphasised.

I wonder how many other menbers have experienced or come across this particular shock failure. :?:
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Re: How to remedy an occassional "Clunk" with raised suspens

Post by Christoph »

Mud Dog wrote:My SFA has had such a clunk ever since I got it, but usually only when turning, and one also feels it in the "floor boards". Of course an SFA does'nt have ball joints and it was still there after fitting OME so I ruled out the suspension. The u-bolts are the right way around, not that either, I even thught it may be something with the steering box / pitman arm but then I would feel it in the steering. No play in the steering arms, so it's not that either. Neither is it loose calipers. That only leaves the axle ifself, and I wondered if the half shafts were 'floatng' a little (if that's at all possible) and clunking as they slid from one side to the other with centrifugal force in a turn. It's never been a problem as such, just an occasional reminder that something ain't 100's. So many SFA owners exprience these 'clunks' that I almost consider it to be 'normal'.
I have this clunk that you speak of! Its driving me insane!...if I turn a left corner over a bumpy road, or break quite hard on a bumpy road in a straight line, it feels like someone is knocking against the floor board under my feet with a small hammer, can hear it and feel it. I have checked numerous times, there is nothing loose anywhere in that vicinity...in fact there is actually nothing at all under the floor boards on the drivers side!!!...have you ever figured out what the clunk was? Anybody?
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Re: How to remedy an occassional "Clunk" with raised suspens

Post by Mud Dog »

It's quite common with SFA's and I've never been able to pin-point it despite checking and re-checking the whole suspension. It's also not apparently something of a serious nature, since there would have been a failure of some kind over time (many years).
I just learned to accept is as being 'normal' and suspect that it may have something to do with the leaf packs themselves ... either the whole pack shifts on the pedestal around the location pin, or the leaves themselves shift within the packs, as this only happens when they come under certain stresses like twisting when one turns in a certain direction. The reason why it feels like it's underfoot is probably because the shackle mount is in fact right there, transferring the vibration / shock into the chassis at that point.

It can be unnerving, but learn to live with it. ;-)
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Re: How to remedy an occassional "Clunk" with raised suspens

Post by Christoph »

Thanks for that!...guess i'll just have to learn to ignore it
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Re: How to remedy an occassional "Clunk" with raised suspens

Post by Harold »

Intersting topic as I also have a very occasional 'clunk'. Other than having an extra leaf in the rear my suspension is standard.
At least I now have a starting point to try and find the 'clunk.'
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