Date:         Wed, 4 Nov 1998 22:08:17 -0500
Reply-To:     Mark Gajewski <mgajewski@MANVILLERUBBER.COM>
Sender:       Vanagon Mailing List <vanagon@vanagon.com>
From:         Mark Gajewski <mgajewski@MANVILLERUBBER.COM>
Subject:      steering still clunking
Comments: To: vanagon@vanagon.com
Content-Type: text/plain; charset=us-ascii

Well, this is what I love about working on my own vehicles, I always end
up fixing more than I need to...and much of what doesn't need fixing at
all as well!

A couple weeks/months back I checked the archives about steering
clunks.  Found lots of mention of bad upper control arm bushings so I
changed those.  Still clunked (although I did eliminate that awful
squeaking/groaning).  Most recently I thought I traced it to a worn
steering relay gear (transfer box some people call it).  And damnit,
still clunking.  Folks, I need some help before I go broke fixing what
ain't broke.

The symptom is:
1.)  loud "clunck" or "pop" when turning the wheel sharply at slow
speed.  i.e. if I back out of a parking spot with wheel turned hard
right, then start going forward while cranking wheel hard left I hear a
clunck/pop coming from somewhere under the gas pedal.  Definately left
side of vehicle somewhere by my feet anyway.
2.)  If you can picture what it would sound like if you loosened one of
the steering linkage couplings (the ones with two bolts on a diamond
shaped flange) removed one bolt and then left the otherone finger loose
and then went for a drive that's what it sounds like (and feels like
through the steering wheel too).  Mostly noticeable when first making a
sharp direction change requiring lots of steering wheel turning (i.e.
maneuvering in parking lots).  Normally cluncks/pops once, but sometimes
several times as you continue turning the wheel.  This ends up sounding
almost like a clunck/crunch/pop for what it's worth.

Does anyone have any clue what could be doing this in light of the new
bushings and new (used) relay box.  All couplings, clamps, rubber
couplings are tight and look good from steering wheel down to relay box
including coupling on relay box for shaft going to steering rack.  Does
the u-joint ever fail?  could the steering rack itself make this noise?
I am going insane over this...any good way of isolating and locating
source of steering clunck noises would be greatly appreciated.

Thanks
Mark