Rear Clunk with all new bushings
 

I recently replaced all my bushings with the Power Flex Poly kit and new pillow ball bushings. I haven't driven the car much because of the weather. I took it out today.

I noticed a fairly loud clunk in the rear. Initial stop & go does it, but it is really noticeable when I pull into my driveway over the slight bump of the street. It seems that the up and down suspension travel makes it the loudest.

I will obviously be putting the car in the air to double-check everything and get this sorted out. I was just wondering if you guys had any idea's?

I am thinking Diff mount...... but not sure.

Thanks

Was this clunk present before you did all this work?

It probably is your diff bushings

Yes, it was. I just figured it was my pillowballs or worn out diff bushings. I will undoubtedly sort this out, I will try to get it in the air today.

I did notice the 4 upper diff mount bolts were very hard to reach when I was putting everything back together, let alone torque them to spec. I did my best, I will double check everything.

Well, the new bushings themselves were nice and snug in the mount. I am thinking I didn't get the 4 top nuts of the mount tight enough. I will of course, check the 2 bushing bolts also.

Thanks guys.

Well, I think I have it sorted.

I jacked up the rear, removed the wheels, and looked it all over. Everything seemed tight. I jacked up each lower control arm for full suspension travel. I then jacked up the diff. I inspected everything, it looked good.

I looked at the rear sway bar, and bingo!.. I had two issues, the whole at the end of the OEM sway bar doesn't fit perfectly on the link bolt. I torqued the nut down more to make it solid. When doing so, I noticed the right rear bar bushing doesn't fit completely around the bar. It seems to be a manufacturing flaw from Power Flex.

When shaking the bar, it simulated the clunking sound. I think I found it.

I also drove my car after checking it. The noise seems to be coming from the right side, this confirms my thoughts.

I will be emailing JKL to see if I can get a replacement bushing. This should fix it. ;)