Need help with front end clunk

From: Karl Kromer (karlk@ssl.berkeley.edu)
Date: Fri Oct 16 1998 - 14:08:54 EDT


I've got a 96 Club Cab 4x4 that has slowly developed a major clunk in the
front suspension. At first, I only noticed it when turning the wheels all
the way one direction, then the other. It would make a noise which I
assumed was just minor play in the tie rods. Then, I started noticing a
muted "clunk" that I could actually feel in the floor board. This would
occur when going up a particularly steep hill that has flat sections,
causing the suspension to unload when going over them at speed.

Last July, at 35k miles, I brought the truck back to the dealer to have
several things fixed under warrantee. I mentioned the clunk, and got the
truck back with a "could not duplicate". However, I noticed every grease
fitting had been stuffed with grease (though I lube it regularly). The
noise was gone for a few days, but is now back (at 40k miles).

Yesterday, I went through an intersection that requires a sharp right,
followed by a sharp left. When I went into the left, there was a very loud
CLUNK from the right front of the truck, and I could actually feel the
truck move as if that wheel had just skipped a few inches.

I'm beginning to suspect there is a major problem somewhere, and my dealer
might have tried to cover it up. I have to take the truck back next week to
have three items fixed that they had to order parts for (which somehow got
misplaced, thus the 3 month wait). I've had good experience with this
dealer on a previous Dakota, so I'm a bit surprised. Needless to say, I
will "duplicate" the problem for them.

Anyone been through something like this? I find it hard to believe there
are worn suspension parts after only 40k miles, most of which are just
cruising on the freeway. No serious off roading, either.

I'm probably moving overseas next year, and have to get a car that I can
take with me (16mpg gets expensive at $4 per gallon). Selling my Dakota
won't be easy with this noise.

Thanks

-Karl



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