Front End Clunk

[pridanc]

Hey guys, after storing my 2002 Protege5 in a building for some years, seems my daughter could use it so I've pulled it out and started to check it out.

Everything works as I remember but there is a clunking sound coming from the front end that I hear when I cross the RR tracks near me or any sharp bumps and so far I can't find the source. I've checked sway bar bushes, sway bar links, control arm bushes, shock mounts etc., with no luck. Realize, that none of that means I may have tried hard enough so speak up.

So far the ONLY thing I've touched or pried on that is at all loose is the radiator. Not much but I can move it in its mount. Any suggestions as to where I should look? I've not tried to move the engine/transmission around but am happy to give that a go.

Call me confused, lost, or both and really need y'alls thoughts. HUGE thanks.

 

[misnblu]

Have you corner bounced the front end yet?
That usually helps finding clunks and squeaks.

You can also lift the car in jack stands and manipulate the front tires in different direction helping find bad bearings, tie rod ends, and ball joints.

 

[pridanc]

misnblu, many thanks for your thoughts but unfortunately for me, yes, I've done all that. I've even pulled the wheels (after pulling, pushing etc in all directions) and have used a jack in several places on each control arm, pry bars under the sway bar etc., etc. to find or create movement all to no avail. IE, I've found zero slop in anything.

So far I have found that the heat shield bolted to the exhaust down pip as it curves under the engine had lost a bolt so can slap easily when you hit a bump etc. I've removed it but have yet to drive the car. That will happen soon. Hard to believe this is what I was hearing but I do know that metal things hitting can have their noise augmented through other metal bits around it and then into the cockpit. I'll find out soon enough even if I find this hard to fathom. At least it is a "thing".

Next, I found some of the plastic air deflectors mounted under the car between the radiator and engine (not 100% sure what they do but for sure some kind of air management) that had lost bolts or had broken an ear or too so could also easily flap over bumps, ultimately slapping on metal structure. Fixed that but too, this is hard to fathom as the culprit. Need to drive it before I make a decision.

Next, although the rubber grommets that hold the water radiator in place are still there and indeed "insulating" the rad, the rad can bounce effortlessly up and down 4 mm. I've no doubt that this too can make noise as it passes through the surrounding metal structure of the car but like a broken record, I need to drive it, once repaired, to decide if this has anything to do with it.

And lastly so far, the goofy engine air intake that pulls in air from the passenger side of the car (roughly, but more like above the rt hand side of the radiator if you can picture that) is loose where it attaches to the box that holds the air cleaner. Because the rubber piece that seals these two parts when joined has crumbled, there is now slop at the joint and even though the little latch that holds these two together is still intact, now with the rubber seal bit gone. these two parts do have slop and a bump will make them bounce up and down from each other and make some noise. As the broken record, hard to fathom this can be any of the noise I hear inside the car. Point being. I am trying hard to find a/the culprit.

I've also pushed and pulled on the exhaust system front to back but find zero movement in any of that.

Any more thoughts are welcome but no matter what, I will get back here to share what. if anything, is ever found for the next poor soul. HUGE thanks to this community.