Clunk in Front End - Fixed

[LazyLightning75]

Finally had a free weekend and decided to lube the front axle and chase down a clunking noise in the front end. It is becoming more frequent and you can hear and feel it through the front floor. I cannot reproduce the sound with the wheels on or off the ground and have tried to wiggle and shake every part I can think of. Even had the kid jump up and down in the bus. Shocks are new and tight, new tie rods, drag link, steering stabilizer. Haven’t touched the ball joints but when I bought the bus 5 years ago they looked newer (at least the boots did). They are Meyle and the boots are still in great shape.

The noise seems to occur when the front end articulates. Happens backing out of the garage and at higher speeds. Does not seem to happen at any regular frequency with bumps, speed, braking, or hitting/backing off the throttle. It is kind of random but does seem to be happening more often. It’s driving me nuts. Any suggestions on where to look next would be greatly appreciated including whether the ball joints might be the culprit.
_________________
1975 Riviera 1.8L FI

[aeromech]

Ball joints since you say the shocks are good
_________________
Lead Mechanic: San Diego Air and Space Museum
Licensed Airframe and Powerplant Mechanic
Licensed Pilot (Single engine Land)
Boeing 727,737-200-300-400,757,767
Airbus A319,320,321
DC9/MD80
BAe146
Fokker F28/F100
VW type 1 1962,63,65,69,72
VW Type 2 1971 (3 ea.) 1978, 1969
VW Jetta
VW Passat
Capable of leaping tall buildings in a single bound

[Cap10323]

I'm currently dealing with the same thing. It's gradually gotten worse over the last year. It's irritating, because other than the noise the bus drives perfectly. You can't feel anything in the steering, only a little bit though the floor.

I'm 99% sure it's one of the front ball joints, even though they have under 10K miles on them. I am going to be replacing them with higher quality ones and hoping that fixes the issue.


Things I have checked that maybe would help you:

Beam attachment bolt tightness
Beam arm spring bolt tightness
Tie rods
Bump stops
Wheel bearings
All brake hardware retaining bolts
Insured there was plenty of fresh grease in the beam bearings.


For me it's only on one side, definitely the front left. And usually only if the suspension decompresses fast. Like going over a speed bump quickly, or backing out of a driveway with a lip.

Because of the way the torsion bar suspension is designed, it seems to be very difficult to check ball joint play without removing the knuckle. Since the joints are in constant tension.
_________________
-Ian

'77 Westfalia - 2.0 F.I

[LazyLightning75]

Thanks Aeromech and Cap. Situation sounds very similar to Cap’s. I swear my problem is on the driver’s side but my son can also feel the clunk in the passenger side too. Might just be the noise is transferring or i have more than one bad ball joint. Sounds like it’s time to check them since I don’t know when they were replaced last. Your list is good and I haven’t checked the wheel bearings but I’m guessing it’s time to service them too. Just about every other item I’ve covered.
_________________
1975 Riviera 1.8L FI

[mikedjames]

If you can take off the rubber boot and then press in some molybdenum disulphide grease into the gap between the ball and socket, then jack up the ball joint and rub in more grease, and repeat you may be able to get the creaks to go away.

I did this instead of replacing some creaking ball joints a few years back.
_________________
Ancient vehicles and vessels

1974 VW T2 : Devon Eurovette camper with 1641 DP T1 engine, Progressive carb, full flow oil cooler, EDIS crank timed ignition.
Engine 1: 40k miles (rocker shaft clip fell off), Engine 2: 30k miles (rebuild, dropped valve). Engine 3: a JK Preservation Parts "new" engine, aluminium case: 26k miles: new top end.
Gearbox rebuild 2021 by Bears.

1979 Westerly GK24 24 foot racer/cruiser yacht Forethought of Gosport.
1973 wooden Pacer sailing dinghy

[SGKent]

My 1971 got creaks and groans from small rust flakes in the beam, from being in water too deep once. Had to pull it apart, take out the grease, clean off the leaves and regrease.
_________________
“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[alschnier]

I have a '71 w/ the same clunk

[Cap10323]

[jakokombi]

I don't know how the sway bar might produce a clunk, but have we checked there?
_________________
70 Sunroof Kombi
69 Tin Top
73 Thing
72 Baja

[LazyLightning75]

The driver’s side sway bar clamp was never installed correctly. It’s about half to two thirds clamped on the metal slide piece, but judging by the rust on it, it has been like that since installation. I’m guessing whoever installed it just said, screw it, close enough. Bushing still looks okay and even with the half ass clamp job, it feels pretty solid.

I have new ball joints ordered (already pressed into the included arms) and new clamps for the sway bar. I’ll inspect and grease the wheel bearings while everything is apart, and change the flexible brake lines. It’ll be an adventure in auto repair reading about the lifespan of new ball joints boots and sway bar clamps that don’t exactly fit.

Any suggestions on other maintenance to include or tips to get the job done are appreciated. I have the Bentley and have read a ton of archived posts to hopefully tackle the job without too many cuss words.

_________________
1975 Riviera 1.8L FI

[jakokombi]

If one of the sway bar end bolts is loose, it may produce a clunk. A sloppy bushing can't help.
Good luck!
_________________
70 Sunroof Kombi
69 Tin Top
73 Thing
72 Baja

[LazyLightning75]

Installed new ball joints and now she’s as quiet as a mouse. It was also a good opportunity to grease the wheel bearings, install new seals, replace the soft brakes lines, and install new clamps on the sway bar. What a difference and pleasure to drive. Thanks for all the Samba input!
_________________
1975 Riviera 1.8L FI

[Elibomrod]

Have you thought about a broken leaf in the torsion bar…
That’s what the problem was on mine.

More likely to happen in a lowered bus, not quite sure of the logic…

[LazyLightning75]

I figured out how to change the title of this thread too. Fixed. New ball joints did the trick and got rid of the clunking noise.
_________________
1975 Riviera 1.8L FI