Contour Enthusiasts Group Archives Forums Modifications Suspension Rear suspension clunk

this might be the case, but I doubt it will cure my problems since it made no noise before I had the suspension replaced and subframe boxed. Chassis flex wouldn't all of the sudden appear like that would it?

"it made no noise before I had the suspension replaced and subframe boxed." Is it possible that you've just provided a key clue to your problem?

Who did the work? What was done and what parts were replaced? Was the subframe removed from the chassis to be "boxed", as you call it?

Something as simple as installing the sway bar backwards (LH vs. RH) will create a clunk. Don't laugh 'cause I've seen it done....

Whenever I do a subframe job, I always reassemble all the components and cycle the suspension through it's up/down motion while the complete subframe and suspension assembly sits on the garage floor. I can clearly see everything and am assured that all parts are functioning properly without any binding or rubbing.

To answer the questions:

My dad's shop did the work, and yes the subframe was removed from the car. The subframe brackets were welded and reinforced. I think the ABS sensors or something were replaced as well (apparently they broke when he took them off). Rear rotors and pads were changed, as well as shocks and struts.

You've got me thinking about the backwards sway bar...that could be the problem. Isnt' there a kink in the bar on towards the one side (i though it was the right side). If so, I could see how switching it would make a difference and cause a clunk. How can I make sure its not on backwards?

The kink should be on the passenger side of the car.

thanks stazi, i'll check it out as soon as i can

Checked the sway bar, kink is on the passenger side so it must me on correctly. I did notice that the sway bar is extremely close to the subframe though, I might be able to slide a piece of paper inbetween the bar and the subframe....not sure if that would be making the noise or not.

It is normally very close to the subframe. Unfortunately, the only way I know to find out for sure is to remove it and see if the paint is still there or worn off.

Are all the other rr suspension components in good condition? End links go regularly, control arm bushings wear out with time, upper strut mounts too. And on and on....

You didn't mention-is your car lowered? Is your sway bar stock or aftermarket?

I just put BAT springs and Bilstein struts on the car. The strut mounts seemed fine, although I'm not quite sure how to tell if they are bad or not, but they didn't make any noise before the suspension was changed. I also have a BAT sway bar and just had the subframe boxed as well..although i've had the bar on there for about 3 years. I relpaced the endlinks about 3,000 miles ago. All the other bushings and what not seemed alright. This whole thing seemed strange...just because the noise suddenly appeared after I had the suspension work done.

Spring possibly not seated just right.

Yeah I thought about that too, and I realized the mechanic didn't put the plastic covers on the top coils of the rear springs (from the stock ones) so I took the struts and springs off and put them back on, but it still makes the noise. I got my dad to drive it around a little while I laid in the trunk, and the noise seems to be coming from a little lower than the spring perch area.