Suspension rattle and RE:Clunk when engaging

["Jan Wikström" <104707.3644@CompuServe.COM>]

Message text written by Matthew Waite
>Any suggestions...help???<

A simple test for the clunk is to jack up the rear of the car and get
somebody to twist the bejasus out of the rear wheels while you crawl under
to locate the source of the noise and movement. With all U-joints replaced
and the gearbox in good order, about the only remaining suspect is  the
final drive - especially likely if the person replacing the U-joints
tampered with the input shaft nut, as the bearing clearance is determined
by a crush spacer and this nut must NOT be disturbed (changing the pinion
bearing clearance can increase the backlash in the drive, as well as ruin
the bearings).

Much the same strategy applies to the front suspension: crawl under and
check all the new bushes. It can be something quite trivial; I had one of
the links to the front sway bar wear through its washer, giving it freedom
to push into the rubber bush and pull out again; it made the most
astonishing (and frightening) noise. Don't foget the upper shock absorber
mounts (visible under the bonnet); they're under-dimensioned and the metal
around them can crack.

- Jan

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