Clunk sound determined (pic) now a fix?

zband · 06-11-2007, 05:24 PM

For the longest time I could not figure out why when I crept slowly over uneven ground why I would here a distinct *clunk* from my rear drivers side. Today I tracked it down to the sway bar

the bolt and nut are tight (at least 200 ft pounds of torque), yet even pushing the sway bar upwards, I can see and hear the bolt inside move. I took off the bolt expecting to see the bushing shredded or damaged but it was OK. How do I fix this? I could take it to a shop and apply massive torque but at 250 it should have tightened (maybe needs more torque?) or do I replace it - if so I'm looking for something that would last longer...

zband · 06-12-2007, 07:45 AM

any thoughts?

**Terrain Twister** · 06-12-2007, 08:11 AM

Are you saying the hole is elongated inside? If so, maybe clean it up and throw in a bushing?

zband · 06-12-2007, 08:14 AM

No the hole in the bushing seems perfect. So this is where I am confused- where the play is coming from? If its from the bushing I could replace it (any thoughts on replacement bushing is appreciated) or lack of torque on the bolt?

can a bushing fail and look perfectly normal?

BTW 55K on the Jeep.

FF151DJG · 06-12-2007, 08:22 AM

maybe the rubber bushing isn't showing signs of wear but has lost its structural integrity and not hold as tight as it should. i don't see that bushing costing alot of money i would try changing it out and see what happens.

SpitNine · 06-12-2007, 08:24 AM

Quote:

Originally Posted by zband

For the longest time I could not figure out why when I crept slowly over uneven ground why I would here a distinct *clunk* from my rear drivers side. Today I tracked it down to the sway bar.
The bolt and nut are tight (at least 200 ft pounds of torque), yet even pushing the sway bar upwards, I can see and hear the bolt inside move. I took off the bolt expecting to see the bushing shredded or damaged but it was OK. How do I fix this? I could take it to a shop and apply massive torque but at 250 it should have tightened (maybe needs more torque?) or do I replace it - if so I'm looking for something that would last longer...

Also check the rubber bushings where the sway bar is attached to the frame. These can harden and allow the bar to bang around inside the bushing making considerable noise.
This (hard bushings/loud noise) is a very common problem with both the front and rear sway bars on high mileage Hondas. Fortunately, it's an easy and inexpensive fix. At least on a Honda.

Thanks.

rjt36 · 06-12-2007, 09:50 AM

Why are you torqueing it to 200? The most I've ever torqued anything down on my Jeep was 180, and that was really hard and on a pinion nut.

Those nuts should only be torqued to 40 ft. lbs. Try starting there and see if your noise goes away.

Chris_ · 06-12-2007, 11:09 AM

Mine did that. Your axle twists, and that bushing allows the movement. Eventually, it will wallow out enough that the bolt can move around inside. Take the bolt off and wrap it in teflon tape. Put it back together and your clunk will go away. Just need to add more girth to the bolt so it won't move around inside the bushing. Going on 10 months with this home brew repair.

zband · 06-12-2007, 11:26 PM

OK I fixed it using a combination of Chris_ suggestion and my own. I took both of the bolts out and inspected them. It turns out that on the side that was the loudest , the sway bar had compressed the threads on the bolt- so the nut (after time had worked its way off) could not be tightened past the point of the damaged threads. This is the reason that I could not torque the bolts on and bar was loose.

Since I could not find a replacement bolt I instead put some washers between the sway bar and the bushing, in addition to wrapping the bolt with teflon tape. Tightening the nut now compressed the bushing.

Done. No more clanking when I creep along. Silence is truly bliss!

I know that this is a temporary fix but it will do for a couple of months.

Thanks !!

**Rocky529** · 06-13-2007, 05:48 AM

Keep them torqued to 40 ft/lbs only.

**numchuck** · 06-13-2007, 07:57 AM

I have no idea what is causing your "clunk" . . . but I will bet you a beer that it is not the sway bar end link . . . look carefully at the brackets that attach the bar to the axle . . . and also check the bolts that attach your track bar to the axle and the frame . . . or maybe one of your shocks is loose . . . but whatever it turns out to be - try to find the proper torque spec - 200 pounds on the end link is about 5 times too much .

Chris_ · 06-13-2007, 08:24 AM

Quote:

Originally Posted by numchuck

I have no idea what is causing your "clunk" . . . but I will bet you a beer that it is not the sway bar end link . . . look carefully at the brackets that attach the bar to the axle . . . and also check the bolts that attach your sway bar to the axle and the frame .

He'd be a fool not to take that bet. Obviously, if he's done some work and the noise is gone, I'm going to say he'll win that bet.

lupinsea · 06-13-2007, 01:54 PM

Nice touch with the washers. Why didn't I think of that?

I found I had the same issue. . . the bushings look find but with all the flexing out from trail running the hole looks wallowed out a bit. Both top and bottom holes, for me.

Thanks again for the washer trick. Replacing those end links with new ones are pricey for what are plastic end links and I don't know where to get replacement bushings.

**numchuck** · 06-13-2007, 10:21 PM

Quote:

Originally Posted by Chris_

He'd be a fool not to take that bet. Obviously, if he's done some work and the noise is gone, I'm going to say he'll win that bet.

guess I should read more carefully . . . my bad . . .