quick run down on my jeep. 97 cherokee with 205000 on body. recent work performed on front end- new brakes installed alloy usa axle tube seals 2 weeks ago, 1 month ago serviced diff ( no metal shavings in old fluid) also installed rustys steering conversion at same time.

complaint- two days ago i started getting a clunking sound for the first 20 feet and then it goes away. the only time it does this is when i first get moving in the morning or 8-10 hrs later after sitting. it sounds like its coming from the driver side front. currently the front drive shaft is out.

known issues on front end- passenger u-joint has wear, upper control arm bushings and balljoints possibly original but dont show any signs of major wear. steering gear box has minimal play on output shaft. no signs of cracking around gearbox. unibody has been reinforced and gearbox tied in to passenger frame rail.

when i did the brakes i checked for play in balljoints and hub and there was no slop. i have also checked for play in the front yoke and there is very minimal if i had to guess id say 1/32 - 1/16th of an inch of play in yoke.

 

Sorry i dont have your answer but i just did a rustys steering conversion and i now have a slight popping noise in the front end also from the drivers side. i was just about to start a thread aswell.

 

You said it occurs within the first twenty feet, does it pop once or multiple times, does it pop when making a turn? If it does check your control arm bushings and make sure the control arm bolts are properly torqued down.

Highlander, does it pop when making a sharp turn or anytime you turn the wheel? Have u checked That the TREs are properly torqued down and in good shape? Look for excess movement or play in the steering linkage to locate the problem area. Try pivoting the linkage by hand, also have someone turn the wheel while you look at it to determine the problem area.

 

it does do it multiple times. in regards to the rustys steering conversion make sure those damn jam nuts are tight. i torqued mine to 40 ft lbs to keep them from backing off. also depending upon how much lift you have the draglink may be hitting ur passenger sway bar mount when turning.

 

Hmm check your engine and tranny mounts.

Edit: will post more about it after class

 

After your second post i did a search on popping in the front end. Which brought me here:
https://www.cherokeeforum.com/f2/pop...114493/index3/
^ read post 32

Transmission mount info:

https://www.cherokeeforum.com/f2/tra...on-mount-6373/

https://www.cherokeeforum.com/f2/tra...question-6960/


Search, The answers are already out there.

 

transmission mount is new, and that issue sounds different than mine, but i appreciate you posting that.

 

check the engine mounts as well. when under a load then engine can move around and make a popping/ clunking if the mounts are worn out.

Also check your exhaust manifold for cracks or loose bolts. I know you said it sounds like its coming from the drivers side but its worth a check...

if its neither of those.... I'll have to do some research

 

looked at all mounts bushings in front end today, all look good. motor mounts done 10k ago. upper cntrl arm bushings look good. didnt see any cracks in the rubber. trans mount has 10-15k on it, im starting to think its that u joint, or a steering box spacer.

 

just for info it was the knuckles on my old 30. they had deep grooves where the calipers road. im guessing that in the morning between them colling off and stuff they settled. after a couple of brake applications they resettled and quit making the noise.

 

Thanks for the update. Mine intermittently does the same thing. I bet this is the problem.

 

look at where you're caliper rides. if you see any grooving this is it.

 

i know this is an old thread, but were the knuckles 100% the issue? I am having the exact symptoms you described. The shop i took it to said it was the front differential, but dont do diff work and cant repair it. So its hard for me to trust their answer.