L Body has weid Clunk

[jmgtp]

This is a repost (my original is on Beretta.net) but I know theres some L body experts around here that may be able to help as well:

In regards to:
1990 Beretta GT
3.1/5 speed
104k miles

I have a front end clunk that I can't seem to isolate. It seems to only occur when I first start to accelerate from a stop (doesn't do it if I granny accelerate) or if I am in motion and hit the brakes a lil bit harder than you normally would when coming to a stop (when it does it under braking it will do it in gear or in neutral). It doesn't seem to make the noise when going over bumps or turns, at speed or slowly. It will also make the noise if I left off the gas abruptly in 1st gear at speeds over 15-20 mph (5 speed), sometimes in 2nd gear - never in higher gears. Since the clunk is evident under braking even when the transmission is in neutral that leads me to believe it is not something in the driveline but rather the suspension.

The following items are brand new (replaced last week when I did the clutch - noise was there before I did the clutch too) and I don't suspect any of them to be the source of the clunk since I have checked them for play and wear so many times:
-Front Motor Mount
-Upper & Lower Trans Mounts (trans clears frame rail for sure)
-Poly Control Arm Bushings
-Sway bar end links
-1 new ball joint - other good
-1 new axle - other good
-New front calipers & pads

I think those are most of the items that would cause this clunk (which if I had to guess I would say drivers side but very hard to tell from inside the car). I can't seem to find anything loose either. I'm starting to think it may be something in the strut assemblies. The upper mounts seem ok but I don't know of a good way to test them; they appear firm and solidly in place. At one point in my search I removed the sway bar just to make sure it wasn't the source but the sound persisted (sway bar is reinstalled now). I did do a search on the forums but I came up with the usual: check the control arm bushings, ball joints, etc - all of which are new or good in my vehicle. Also: when the clunk occurs, sometimes it is louder than other times depending on how hard I accelerate or brake; when it does it loud I can very slightly feel it through the car and the pedals, not so much in the steering wheel though.

Thanks for any info!
-John

[bbeck]

I'd check the rubber bushings that mount the sway bar. they usually wear through and cause what you're describing. my 88 beretta had that. I have it apart right now. and I don't see them on your list yet. they're kinda tough to get to, good luck

[jmgtp]

I solved the problem a while back, I just didn't post a follow up since no one responded. But since you responded here it goes:

Stupid me torqued the 3 strut bolts/nuts (for the upper strut mount) with the wheels OFF the ground. So the weight of the assemblies on the bolts gave a false torque reading. I re-torqued them with the wheels on the ground (hence the assemblies pushing up into the strut tower rather than resting their weight on the bolts) and the clunk ceased. So... it was the front strut mounts knocking around just a bit.

[tranceokido]

I have this same clunk when going to brake or when I first start off in gear or reverse. I should check this out since I have replaced both front struts.