04 XJR: Rebuilt front end, stil have a clunk!
Well, I finally got the car back on the road after doing a bunch of work including new sway bar bushings and new lower control arm bushings. It has relatively new upper control arms which feel tight. The upper and lower ball joints are not showing any looseness. The tie rod ends are tight. The sway bar link feels tight. But when I hit a sharp bump on the right side I still hear a clunk or chatter. Does anyone one have any ideas? Is there something in the shock that can make noise or something on top of the shock? Maybe there is something clunking inside the dash that sounds like the suspension. Has anyone ever had a clunk in their dash?
Did you check the lower shock bush, which is located in the lower wishbone ? The front shock has a fork at the lower end to located on this with a through-bolt. These bushes have a short life as the whole weight of the car rests on the four shock bushes.
I have just found out by reading this forum that the crash tubes can become loose and
noisy. TSB here:
Jaguar Workshop Manuals > XJ (X350) V8-4.2L SC (2004) > Body and Frame > Bumper > Front Bumper > Front Bumper Shock Absorber > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Bumper Shock Absorber: > JTB00
noisy. TSB here:
Jaguar Workshop Manuals > XJ (X350) V8-4.2L SC (2004) > Body and Frame > Bumper > Front Bumper > Front Bumper Shock Absorber > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Bumper Shock Absorber: > JTB00
Well I found the noise. Its was the hardest kind of problem to find, man made problem. The RF upper control arm bolts were loose. They were replaced recently by someone before I bought the car and I guess they didn't tighten them enough. So put that on the list I guess for suspension noise checks. Go over all the mounting bolts and make sure they are all tight. I know its kind of obvious now, but while changing the other parts I didn't think to examine the new parts.
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