Clunking from the rear end... - FOUND THE CAUSE

[ZetecVan 2.0]

Got a strange one on the van. Last week a clunking started around the N/S/R when I hit a bump (and there are lots on Bradfords roads), so I checked underneath and the exhaust mount had broken. So, I replace them yesterday and went out last night.

 

It was fine to begin with then later when I either accellerated hard from a standstill or the N/S/R wheel hit a bump there was a loud clunk.

 

I've just been out and checked the exhaust, the spring hangers, the panhard rod, the link bars and the shocks and can't find anything loose.

 

It's been jacked up and I've pulled and prodded everything and can't see what's wrong. I was beginning to think it was the LSD, but why would it clonk when I hit bumps in the road?

 

Any ideas?

[antz]

knackered damper?

[johnny_h]

Have you got radius arms?

[ZetecVan 2.0]

Have you got radius arms?

 

There's a modified escort link kit under there, which is rose jointed. Only two lower links are fitted. There doesn't appear to be any play in any of the joints.

 

I don't think it's a knackered damper because the it did it on a flat wet road last night as I pulled away from the petrol station.

[johnny_h]

I was getting clunking when my radius arm bracket snapped off the axle. To look at it everything seemed normal as the radius arm and bracket was resting in place.

[ZetecVan 2.0]

I think I'll take the arms off tomorrow and have a proper look at the rose joints. I noticed the other week that one of them on my adjustable TCAs has a bit of play.

[Anglia68]

I'ld be interested to know what's up Mike.

 

The TCA's have been on for about 10 years and the anti-tramp bars for about 7 - 8.

[Toby]

Have you tried eating more fibre?

[4parajon]

Is it still under warranty Mike??

I'd take it back to the previous owner

[Rick]

whay kind of exhaust mount did you use. i found that mine does the job but on large bumps the exhaust swivels round the rubber and then clonks the back panel

[Toby]

I'd take it back to the previous owner

 

[ZetecVan 2.0]

whay kind of exhaust mount did you use. i found that mine does the job but on large bumps the exhaust swivels round the rubber and then clonks the back panel

 

The mounts were fitted by Tony Law Exhausts when they did it two years ago. It's been fine until now. They are two bobbin type ones fitted to the crossmember running under the rear floor. I've pushed and pulled the exhaust and it doesn't seem to be banging on anything.

[Toby]

How about a broken engine or gearbox mount?

[awesome]

Mike i had a clunking coming from my back axle before on my way to a show, so i stopped at the roadside couldn't find any thing loose so i started up again and the clunking had gone then after about five miles it was back worse than before so i got the tow truck out, When i got it home and took the back wheels off i found the rear wheel bearing had snapped and all the ball bearings had come out, So check the wheel bearings

i couldn't believe how loud the clunk was, i thought the prop shaft

was coming off it was that loud

Hope this helps Wayne

[ZetecVan 2.0]

Cheers Wayne, I'll check that out. The bearing on that side was replaced last year after collapsing and that was more of a continual grating sound, and there was oil leaking out. Still, it could have collapsed again!

 

I didn't get chance to look last night as it was raining, but I think I'll go out there now.

[ZetecVan 2.0]

I checked the bearing out and it's fine.

 

When I drove off down the road it sounded like the banging was coming from under the passenger floor, so that's the exhaust. But there's bags of room.

 

However I noticed the prop seems rather close to the removable crossmember, so I reckon it's hitting it. I couldn't have a proper look as it started pissing down again.

[ZetecVan 2.0]

Well I found the cause. Because the prop seemed too low, I pushed the gearbox but it was loose. But how? I'd checked the crossmember mounts and they were bolted up tight.

 

This is how.

 

 

Where the crossmember was modified to allow the exhaust manifold to pass through, the steel has snapped in half. The welds are fine. The steel must have been too thin to cope with the stresses of two years of flooring it.

[escort21]

Oh thats a new one ...glad you found it

[Toby]

 

That is quite broken!

 

We want photos of the repair please

[ZetecVan 2.0]

 

That is quite broken!

 

We want photos of the repair please

 

I'm on it!

[Anglia68]

That's nasty Mike,glad you found it.

 

Are you going to repair that one,modify another one or make a custom one?

[ZetecVan 2.0]

That's nasty Mike,glad you found it.

 

Are you going to repair that one,modify another one or make a custom one?

 

I should really make a custom one like the Milton one but I want it back on the road for tomorrow for the northern Retro Rides meet. I've just been down to the local steel place and got a three mm thick strip which I'm going to repair it with.

 

So far, I've cut off the metal that I put on during the modification, and welded the original top of the crossmember to hold the two pieces together. I've just come in for a coffee break, then I'm back out to continue.

[Trevmk3]

nice bit of metal pealage , make sure you do a nice job Mike

[Anglia68]

I made mine out of steel strip,a bit of 2mm plate and a couple of short pieces of angle iron.Only took a couple of hours including a very rough coat of Smoothrite.

 

[ZetecVan 2.0]

Especially for Toby

 

Here I've cut off all the crap that I welded on when I modified it the first time. I've welded the two pieces back together using the original top of the crossmember.

 

 

I've used a piece of 3mm strip cut to the approx length and bent in the right places. I don't have a steel folder that does 3mm plate, so did it using a big hammer.

 

I've now welded it in place, using project Rotbox as a jig to make sure it was in the right place.

 

I've welded the top on for a bit of extra strength.

 

 

All I need to do now is make a bit of box type section for more strength.