Clunking over bumps

[Calamaro]

Hi all,

I've got an '08 Aveo5 with over 192,000 miles. Lately it's been making a clunk somewhere in the front suspension system when I go over bumps, even small ones. It makes a little noise in the rear, too, but not quite as much. Doesn't pull to either side, and very little wobble (if any) in the steering wheel.

Here's what I've done, but to no avail:
-Replaced front and rear shock absorbers
-Replaced front and rear wheel bearings and hubs
-Replaced sway bar links
-Replaced inner and outer tie rods
-Replaced control arms/ball joints/bushings

Wheels have no wobble in either the 3&9 positions or 12&6 positions. Tested suspension by lifting car slightly and putting a pry bar under the tire and couldn't replicate the clunk noise.

What's left to try? Sway bar bushings? Crossmember bushings (and how do I even find those parts, let alone replace them)? Any other ideas?

[Eg.h2o]

My guess would be the front strut bushings. I’m not sure if you used a complete strut assembly in a box, or if you just bought a bare strut and reused everything else. If you reused old strut bushings, they may be old and compressed. If you bought complete assemblies, I’ve seen the bushings assembled incorrectly right out of the box. Here is a link to show the correct orientation of the parts. I had to do this on my brand new assemblies.
https://youtu.be/8bOfDpea1EY
that clunk can drive you insane!

[Calamaro]

I re-used the old ones. I guess that'll be my next thing to try. I used that same video when I put the new shock absorbers in, easy mistake to make to put them in upside down, eh?

[Calamaro]

Any way I can test to find out if that's what's up before I disassemble the struts again?

[Eg.h2o]

Not really, but once you “know” that particular sound, you’ll never forget it. With the list of replacement parts you out on, I’m fairly confident this will be your issue.

[Eg.h2o]

Any way I can test to find out if that's what's up before I disassemble the struts again?

shake the car up and down with the hood up, you may be able to trace the noise, maybe not…

[Calamaro]

I replaced the strut mount bushings, bearings, and caps (found online for about $30 total) - all three top pieces above the coil spring top plate and...

...yep. That's exactly what it was!
Thank you Eg.h20!

[Eg.h2o]

Enjoy the silence in your car

[john_johnson]

Hi all,

I've got an '08 Aveo5 with over 192,000 miles. Lately it's been making a clunk somewhere in the front suspension system when I go over bumps, even small ones. It makes a little noise in the rear, too, but not quite as much. Doesn't pull to either side, and very little wobble (if any) in the steering wheel.

Here's what I've done, but to no avail:
-Replaced front and rear shock absorbers
-Replaced front and rear wheel bearings and hubs
-Replaced sway bar links
-Replaced inner and outer tie rods
-Replaced control arms/ball joints/bushings

Wheels have no wobble in either the 3&9 positions or 12&6 positions. Tested suspension by lifting car slightly and putting a pry bar under the tire and couldn't replicate the clunk noise.

What's left to try? Sway bar bushings? Crossmember bushings (and how do I even find those parts, let alone replace them)? Any other ideas?

I had the same clunk, turns out its a rubber grommet that the rear shock/suspension attaches to the straight axle - The GM part is expensive - because the piece comes as one whole unit - BUT my great mechanic found out that a newer volkswagon sedan rubber bushing fit in that hole just fine! Still holding up 100K later

[crtrett]

Check your sway bar frame bushings. Did you check your top shock mounts? Either of these are common overlooks.