Funky clunk sound driving me absolutely insane!

[AirSpeed]

Been hearing a clunk sound on the passenger side of my 72 K1500. Jacked it up and found the ball joints were bad, just got done replacing them, went for a test drive and the clunk sound is still there! Had a friend with me and he can feel it on the floor board board on the passenger side. This happens mostly as I go around a corner. Checked all the tie rod ends, body mounts, recently installed new urethane bushings in the leaf springs, I can't find any source for this sound.
I did notice the front spring perch on drivers side moves a little when I turn the steering wheel, seems two of the rivets are worn, I can wiggle them with my fingers. I'm curious what I can do to fix that? Can I weld the rivets in? I doubt seriously it's the source of noise on the passenger side but I need to fix it anyway.
I am completely out of ideas as to the source of that damn clunk on the passenger side! Any ideas?

[Boog]

Aaron how about shock mounts, cab and radiator support mounts, bumper bolts to frame? It is normal for the leaf spring mounts to move a little bit when turning. Possible cracks in the frame through the steering sector bolt holes?

[AirSpeed]

Originally Posted by Boog

Aaron how about shock mounts, cab and radiator support mounts, bumper bolts to frame? It is normal for the leaf spring mounts to move a little bit when turning. Possible cracks in the frame through the steering sector bolt holes?

I checked pretty good, checked every nut and bolt, cab mounts are in good shape. Took a hammer under there and tapped on everything, even checked the u bolts on the axel. The core support, radiator and mounts are all new but the sound was there before they were replaced. Im thinking of mounting a camera under there and run it to my stereo display and see if I can see anything move as I drive. It actually make two distinct sounds about a second apart as I go around a corner, when I found the upper and lower ball joints were worn out I thought for sure it was the source of the sounds, unfortunately as I said it's still there after I replaced them.
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[Boog]

It only takes a minute amount of movement for heavy metal to make a strong noise transferred through the vehicle. Engine mounts, crossmembers are suspect.

[Boog]

Good point Joe. I have had calipers that didn't fit snug in the bracket and made a hard bump/clunk noise. The bracket may be worn instead of the caliper.

[hamjet]

If you have disc brakes check the grommets that go on the bolts that hold the calipers to the caliper frame. when they wear out they make a terrible noise like the front end is falling off.

[AirSpeed]

Originally Posted by hamjet

If you have disc brakes check the grommets that go on the bolts that hold the calipers to the caliper frame. when they wear out they make a terrible noise like the front end is falling off.

Ironically I just replaced the front brakes with new calipers a couple days ago.
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[slomotion]

My vote goes to the right engine mount...........

[kwmech]

upper shock mount bolt loose

[67 chevelle]

first guess control arm bushings
second guess ball joints
third sway bar bushings - if it has one

you can weld the perch , crossmember or trany mont may be lose also

[AirSpeed]

Thanks all, I'll crawl around under that sucker tomorrow with a few extra ideas. I did notice a little while ago my right exhaust manifold is only about 1/4" from the frame while the left is about 5/8" above the frame. Motor mounts are new so I'm going loosen them up and see how much I can twist the engine to even it out. I can't tell if it's hitting the frame but it's close enough to be suspect.
Thanks for the ideas, I'll double check it all tomorrow.

[kwmech]

Originally Posted by 67 chevelle

first guess control arm bushings
second guess ball joints
third sway bar bushings -

It's a 4wd

[El Dorado Jim]

Originally Posted by AirSpeed

Been hearing a clunk sound on the passenger side of my 72 K1500. Jacked it up and found the ball joints were bad, just got done replacing them, went for a test drive and the clunk sound is still there! Had a friend with me and he can feel it on the floor board board on the passenger side. This happens mostly as I go around a corner. Checked all the tie rod ends, body mounts, recently installed new urethane bushings in the leaf springs, I can't find any source for this sound.
I did notice the front spring perch on drivers side moves a little when I turn the steering wheel, seems two of the rivets are worn, I can wiggle them with my fingers. I'm curious what I can do to fix that? Can I weld the rivets in? I doubt seriously it's the source of noise on the passenger side but I need to fix it anyway.
I am completely out of ideas as to the source of that damn clunk on the passenger side! Any ideas?

if the spring hangers are loose it could cause your noise, cut off the rivets, drive them out and install grade 8 bolts ...

[AirSpeed]

Originally Posted by El Dorado Jim

if the spring hangers are loose it could cause your noise, cut off the rivets, drive them out and install grade 8 bolts ...

I'll definitely do that but those rivets are on the drivers side, the sound is definitely coming from the passenger side. You can actually feel it on the passenger side only. It's a mystery! It will probably turn out to be something obvious and I'll kick myself when I find it.
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[67 cst swb]

***Edit*** I just reread this post and noticed its a 4x4, so disregard my suggestion below.
How is your truck lowered? If is is lowered...
I had a set of cut front coils in an old 67 years ago. they were not cut in the right location to line up with the pocket in the lower control arm. So, every time I turned the wheel past a certain point, the coil would thunk into place on the control arm. It was very noticeable and irritating.

[toolboxchev]

Check the bed bolts, I found a few making and extreme amount of ruckus. These frames do flex quite a bit.

[Seanext]

If it still has the transfer case bracket that mounts to the frame the bushings could be worn out making the noise.

[Daves70]

My vote is a cracked frame behind the steering box. Hope I'm wrong. Good luck.

[El Dorado Jim]

Originally Posted by Daves70

My vote is a cracked frame behind the steering box. Hope I'm wrong. Good luck.

I know you said you checked for cracked frame, did you look behind steering box.....?check your steering box for loose bolts.or cracks at the bolt holes for the steering box..kind of stupid questions I am asking, but it is frustrating to me as well not being able to figure it out...

[AirSpeed]

Originally Posted by El Dorado Jim

I know you said you checked for cracked frame, did you look behind steering box.....?check your steering box for loose bolts.or cracks at the bolt holes for the steering box..kind of stupid questions I am asking, but it is frustrating to me as well not being able to figure it out...

I checked it, there are two loose rivits but they're not making any noise, it barely moves but I'm going to grind them off and put some bolts in it. The sound is definitely on the passenger side. It's frustrating as hell! I've been under, over, inside and out of the truck, tightened every nut and bolt, replaced all the bushings, drag link, ball joints, wheel bearings, brakes, tie rod ends, I even cleaned out the glove box and searched under the seat. I tried spraying lube on every component one area at a time to see if I could get the sound to change but no luck. I am at a loss! It's the only noise in my truck, I can drive down a dirt road and have no rattles, just that annoying creaking clunk! I can't wait to find it!

[garyd1961]

I had the same problem. Mine turned out to the exhaust pipe hitting where it goes under the back of the cab.

[outfield]

You said that you replaced the spring bushings, did you also replace the shackle bushing in the frame?

[outfield]

You said that you replaced the spring bushings, did you also replace the shackle bushing in the frame?

[AirSpeed]

Originally Posted by outfield

You said that you replaced the spring bushings, did you also replace the shackle bushing in the frame?

I replaced the bushings at the rear of the springs, upper and lower with urethane but haven't done the front, they still have the rubber bushings I replaced a couple years ago and are in good condition, I have urethane bushings for the front but the weather has prevented me from getting to them, the ones in the front are solid though. I feel like I'm going to find the source one day, probably feel like an idiot when I find it!
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[kwmech]

If you grab the front bumper on the pass side and push it up and down can you hear the noise?
Then bounce the suspension by pushing on the fender