Mysterious rear end "clunk" noise - Zilvia.net Forums | Nissan 240SX (Silvia) and Z (Fairlady) Car Forum

Magoo1222 · 08-03-2016, 11:45 PM

Reposted from general Tech section to S-Chassis section.

Hey guys, for the past few months Ive been tearing my hair out trying to find the source of a horrible drivetrain noise that showed up after putting my car back together for the second time after installing Energy Suspension poly bushings (subframe bushings + all rear arm knuckle bushings) and GKTech rear arms.

Basically, whenever I let out the clutch in gear (more notably a higher gear, low RPM) something is making a horrible knocking noise from the rear end, slightly louder on the passenger side. The noise can be exaggerated by holding the e-brake to bog the car to the point of stalling. The noise is still present with both axles completely removed.

Things that have been tried to solve this include:
New rubber trans mount
Competition Clutch "White Bunny" setup
1 piece Z1 Motorsports driveshaft
New diff side bearings (all internals cleaned and inspected, backlash and preload are perfect)
2 New Car-Quest pass side axles with new circlips for the stub shafts

At this point, I have zero idea what else could be causing this noise. Below are a few videos I took of the car, as well as pertaining info. ANY HELP IS COMPLETELY APPRECIATED!!

https://www.youtube.com/watch?v=IT0q5K29q-s

https://www.youtube.com/watch?v=b8IFY-yfqko

In the second half of this video, I hold the brake to exaggerate the noise
https://www.youtube.com/watch?v=m94L...ature=youtu.be

Relevant car info:
1991 240sx SE hatch
stock rebuilt KA24DE, stock rebuilt transmission (no issues after rebuild)
Competition Clutch "White Bunny" upgrade
z1 motorsports 1 piece steel driveshaft
OEM VLSD rebuilt with Timken side bearings
OEM driver side axle, Car Quest pass side axle (twice)
fortune auto 500 coilovers
full GKTech suspension arm kit with HICAS delete converted to conventional toe arms
full Energy Suspension poly arm and subframe bushings

Magoo1222 · 08-04-2016, 11:38 AM

Anyone have any ideas?

Sent from my Nexus 6P using Tapatalk

lunchmeat · 08-04-2016, 12:13 PM

Jeebus that sounds bad. I'd start removing driveline parts one at a time, checking for excessive play. Sounds like it's coming from the diff to me.

Magoo1222 · 08-04-2016, 12:26 PM

I completely tore the diff apart, cleaned and inspected everything last night. No abnormal wear. No broken or missing parts, no discoloration. Ring and pinion backlash is perfect withing FSM spec, ring tooth pattern is spot on

Sent from my Nexus 6P using Tapatalk

tuzzio · 08-04-2016, 01:04 PM

Are your e-brake cables touching your drive shaft..

Magoo1222 · 08-04-2016, 01:13 PM

No, brake cables are secured in the factory brackets. It is definitely a mechanical metal on metal "clunk"

Sent from my Nexus 6P using Tapatalk

cotbu · 08-04-2016, 04:04 PM

I agree with the differential.
I can hear it actually. For you to rule it out unbolt the driveshaft from the diff. And test it out, if the sound is still there it definitely not the diff. And I'm wrong
Or you could put a screw driver to the differential and get the same or better results.

Sent from my SM-N910T using Tapatalk

Magoo1222 · 08-04-2016, 04:10 PM

As a side note, the noise resonates really loud inside the car and can be felt through the floor. I'm 99% sure it's nothing forward of the diff as the clutch is brand new, and trans is a fresh rebuild (I actually pulled the tailshaft housing off to check the output shaft bearing last week, everything is tight and solid)

Sent from my Nexus 6P using Tapatalk

cotbu · 08-04-2016, 04:24 PM

It's the diff, not that the backlash is wrong or instalation. But it sounds like it's been shimmed. Can you turn the output shafts separately of one another? By hand?

Sent from my SM-N910T using Tapatalk

Magoo1222 · 08-04-2016, 04:27 PM

No, the output shafts don't spin separately unless one shaft is removed. It worked perfectly before I dropped the subframe out to change the bushings, but all I did with the diff was paint it

Sent from my Nexus 6P using Tapatalk

kruked · 08-08-2016, 02:34 PM

I'm wondering if the ears on the output shaft(s) are hitting the floor pan.

jumboflan · 08-08-2016, 10:48 PM

maybe you did mount the subframe back right after the subframe bushings. did the umpkin line up?to subfrme cross member?

*Agamemnon* · 08-10-2016, 06:57 PM

Have you tried using another diff? You can typically find an open diff locally for cheap.

Magoo1222 · 08-10-2016, 07:16 PM

Unfortunately I live in a pretty desolate location when it comes to local used parts, so I don't have access to a known good diff

Sent from my Nexus 6P using Tapatalk

Magoo1222 · 08-12-2016, 11:40 PM

Update on OG problem:

After completely disassembling the differential, thoroughly cleaning, inspecting, and reassembling, I bolted it back into the car. Without either axle installed, I ran the car in gear, low and behold, the original noise is gone, replaced with more of an "annoying" vibration/rattle sound. Im thinking the issue may be with diff alignment on the subframe? Im not sure.

I reassembled everything, and took the car up and down the road, other than a slight rattle upon takeoff, the only noticeable noise now is the pass. rear wheel bearing (which I noticed was on its way out during disassembly).

So I have a new Moog unit ordered and on the way. I will update after I get that problem sorted. Not quite sure what changed the noise, but I wont question it haha.

DiscountPirate · 08-14-2016, 03:34 PM

Did you confirm the driveshaft is not part of the issue? Does it have U joints that could be loose or some type of misalignment, It sounds like you ruled out the shafts, and you went over the diff. It's hard to tell from videos but the sound reminds me of lightweight flywheel chatter. It seems that the sound did not coincide with revs so most likely is some kind of vibrational resonance thing somewhere in the back end.

Magoo1222 · 08-14-2016, 03:40 PM

Quote:

Originally Posted by DiscountPirate

Did you confirm the driveshaft is not part of the issue? Does it have U joints that could be loose or some type of misalignment, It sounds like you ruled out the shafts, and you went over the diff. It's hard to tell from videos but the sound reminds me of lightweight flywheel chatter. It seems that the sound did not coincide with revs so most likely is some kind of vibrational resonance thing somewhere in the back end.

The driveshaft was the first thing I replaced, first by replacing the carrier bearing, and then with a 1 piece Z1 Motorsport driveshaft.

After driving the car a few miles, the only noise I can now hear is the pass rear wheel bearing

Sent from my Nexus 6P using Tapatalk

Mrodriguez124578 · 05-05-2017, 11:24 AM

I have a question. And I am new to this website, but I was thinking about welding my Differential and was wondering about the whole breaking Axles thing. If as of right now I run a 17x10 245/45/r17 in the rear, will that cause my rear Axles to break after a while or would I be okay?

zenkicpe · 05-05-2017, 12:05 PM

Quote:

Originally Posted by Mrodriguez124578

I have a question. And I am new to this website, but I was thinking about welding my Differential and was wondering about the whole breaking Axles thing. If as of right now I run a 17x10 245/45/r17 in the rear, will that cause my rear Axles to break after a while or would I be okay?

alexusbailey_s13 · 05-06-2017, 03:49 PM

I have a similar issue going on. My sounds like a binding noise when Im slowing down. It just started today. No matter if Im in gear or in neutral. It seems like its coming from the center console or passenger side when the noise is made.

Car -
95 S14 Zenki
SR20DE
Z32 LSD
And other shit.

08-03-2016, 11:45 PM	#1
Magoo1222 Zilvia Junkie Join Date: Jun 2013 Location: Upstate New York Age: 28 Posts: 398 Trader Rating: (8) Feedback Score: 8 reviews	Mysterious rear end "clunk" noise Reposted from general Tech section to S-Chassis section. Hey guys, for the past few months Ive been tearing my hair out trying to find the source of a horrible drivetrain noise that showed up after putting my car back together for the second time after installing Energy Suspension poly bushings (subframe bushings + all rear arm knuckle bushings) and GKTech rear arms. Basically, whenever I let out the clutch in gear (more notably a higher gear, low RPM) something is making a horrible knocking noise from the rear end, slightly louder on the passenger side. The noise can be exaggerated by holding the e-brake to bog the car to the point of stalling. The noise is still present with both axles completely removed. Things that have been tried to solve this include: New rubber trans mount Competition Clutch "White Bunny" setup 1 piece Z1 Motorsports driveshaft New diff side bearings (all internals cleaned and inspected, backlash and preload are perfect) 2 New Car-Quest pass side axles with new circlips for the stub shafts At this point, I have zero idea what else could be causing this noise. Below are a few videos I took of the car, as well as pertaining info. ANY HELP IS COMPLETELY APPRECIATED!! https://www.youtube.com/watch?v=IT0q5K29q-s https://www.youtube.com/watch?v=b8IFY-yfqko In the second half of this video, I hold the brake to exaggerate the noise https://www.youtube.com/watch?v=m94L...ature=youtu.be Relevant car info: 1991 240sx SE hatch stock rebuilt KA24DE, stock rebuilt transmission (no issues after rebuild) Competition Clutch "White Bunny" upgrade z1 motorsports 1 piece steel driveshaft OEM VLSD rebuilt with Timken side bearings OEM driver side axle, Car Quest pass side axle (twice) fortune auto 500 coilovers full GKTech suspension arm kit with HICAS delete converted to conventional toe arms full Energy Suspension poly arm and subframe bushings

08-04-2016, 04:04 PM	#7
cotbu Post Whore! Join Date: Sep 2005 Location: SWFL Age: 47 Posts: 3,318 Trader Rating: (3) Feedback Score: 3 reviews	I agree with the differential. I can hear it actually. For you to rule it out unbolt the driveshaft from the diff. And test it out, if the sound is still there it definitely not the diff. And I'm wrong Or you could put a screw driver to the differential and get the same or better results. Sent from my SM-N910T using Tapatalk __________________ LoverTechnologies "Half Broken Things!"

08-04-2016, 04:24 PM	#9
cotbu Post Whore! Join Date: Sep 2005 Location: SWFL Age: 47 Posts: 3,318 Trader Rating: (3) Feedback Score: 3 reviews	It's the diff, not that the backlash is wrong or instalation. But it sounds like it's been shimmed. Can you turn the output shafts separately of one another? By hand? Sent from my SM-N910T using Tapatalk __________________ LoverTechnologies "Half Broken Things!"

08-08-2016, 02:34 PM	#11
kruked Nissanaholic! Join Date: Feb 2012 Location: someone's sisters' pants Posts: 2,288 Trader Rating: (37) Feedback Score: 37 reviews	I'm wondering if the ears on the output shaft(s) are hitting the floor pan. __________________ I like my bikes how I like my b¡tches...naked! 2014 Triumph Street Triple

08-08-2016, 10:48 PM	#12
jumboflan Zilvia Junkie Join Date: Jun 2008 Location: San Francisco Age: 39 Posts: 321 Trader Rating: (2) Feedback Score: 2 reviews	maybe you did mount the subframe back right after the subframe bushings. did the umpkin line up?to subfrme cross member? __________________ Im immune to bullshit....so put your shovel away.

08-04-2016, 11:38 AM	#2
Magoo1222 Zilvia Junkie Join Date: Jun 2013 Location: Upstate New York Age: 28 Posts: 398 Trader Rating: (8) Feedback Score: 8 reviews	Anyone have any ideas? Sent from my Nexus 6P using Tapatalk

08-04-2016, 12:13 PM	#3
lunchmeat Zilvia Addict Join Date: Apr 2016 Location: Southaven, ms Age: 42 Posts: 951 Trader Rating: (0) Feedback Score: 0 reviews	Jeebus that sounds bad. I'd start removing driveline parts one at a time, checking for excessive play. Sounds like it's coming from the diff to me.

08-04-2016, 12:26 PM	#4
Magoo1222 Zilvia Junkie Join Date: Jun 2013 Location: Upstate New York Age: 28 Posts: 398 Trader Rating: (8) Feedback Score: 8 reviews	I completely tore the diff apart, cleaned and inspected everything last night. No abnormal wear. No broken or missing parts, no discoloration. Ring and pinion backlash is perfect withing FSM spec, ring tooth pattern is spot on Sent from my Nexus 6P using Tapatalk

08-04-2016, 01:04 PM	#5
tuzzio Nissanaholic! Join Date: Oct 2013 Location: Western Mass. Posts: 2,254 Trader Rating: (3) Feedback Score: 3 reviews	Are your e-brake cables touching your drive shaft..

08-04-2016, 01:13 PM	#6
Magoo1222 Zilvia Junkie Join Date: Jun 2013 Location: Upstate New York Age: 28 Posts: 398 Trader Rating: (8) Feedback Score: 8 reviews	No, brake cables are secured in the factory brackets. It is definitely a mechanical metal on metal "clunk" Sent from my Nexus 6P using Tapatalk

08-04-2016, 04:10 PM	#8
Magoo1222 Zilvia Junkie Join Date: Jun 2013 Location: Upstate New York Age: 28 Posts: 398 Trader Rating: (8) Feedback Score: 8 reviews	As a side note, the noise resonates really loud inside the car and can be felt through the floor. I'm 99% sure it's nothing forward of the diff as the clutch is brand new, and trans is a fresh rebuild (I actually pulled the tailshaft housing off to check the output shaft bearing last week, everything is tight and solid) Sent from my Nexus 6P using Tapatalk

08-04-2016, 04:27 PM	#10
Magoo1222 Zilvia Junkie Join Date: Jun 2013 Location: Upstate New York Age: 28 Posts: 398 Trader Rating: (8) Feedback Score: 8 reviews	No, the output shafts don't spin separately unless one shaft is removed. It worked perfectly before I dropped the subframe out to change the bushings, but all I did with the diff was paint it Sent from my Nexus 6P using Tapatalk

08-10-2016, 06:57 PM	#13
Agamemnon Premium Member Join Date: Sep 2003 Location: Lake Stevens, WA Age: 38 Posts: 2,585 Trader Rating: (20) Feedback Score: 20 reviews	Have you tried using another diff? You can typically find an open diff locally for cheap.

08-10-2016, 07:16 PM	#14
Magoo1222 Zilvia Junkie Join Date: Jun 2013 Location: Upstate New York Age: 28 Posts: 398 Trader Rating: (8) Feedback Score: 8 reviews	Unfortunately I live in a pretty desolate location when it comes to local used parts, so I don't have access to a known good diff Sent from my Nexus 6P using Tapatalk

08-12-2016, 11:40 PM	#15
Magoo1222 Zilvia Junkie Join Date: Jun 2013 Location: Upstate New York Age: 28 Posts: 398 Trader Rating: (8) Feedback Score: 8 reviews	Update on OG problem: After completely disassembling the differential, thoroughly cleaning, inspecting, and reassembling, I bolted it back into the car. Without either axle installed, I ran the car in gear, low and behold, the original noise is gone, replaced with more of an "annoying" vibration/rattle sound. Im thinking the issue may be with diff alignment on the subframe? Im not sure. I reassembled everything, and took the car up and down the road, other than a slight rattle upon takeoff, the only noticeable noise now is the pass. rear wheel bearing (which I noticed was on its way out during disassembly). So I have a new Moog unit ordered and on the way. I will update after I get that problem sorted. Not quite sure what changed the noise, but I wont question it haha.

08-14-2016, 03:34 PM	#16
DiscountPirate Zilvia Member Join Date: Jul 2016 Location: SoCal Posts: 189 Trader Rating: (0) Feedback Score: 0 reviews	Did you confirm the driveshaft is not part of the issue? Does it have U joints that could be loose or some type of misalignment, It sounds like you ruled out the shafts, and you went over the diff. It's hard to tell from videos but the sound reminds me of lightweight flywheel chatter. It seems that the sound did not coincide with revs so most likely is some kind of vibrational resonance thing somewhere in the back end.

05-05-2017, 11:24 AM	#18
Mrodriguez124578 Join Date: Sep 2016 Location: Rancho Cucamonga Posts: 8 Trader Rating: (0) Feedback Score: 0 reviews	I have a question. And I am new to this website, but I was thinking about welding my Differential and was wondering about the whole breaking Axles thing. If as of right now I run a 17x10 245/45/r17 in the rear, will that cause my rear Axles to break after a while or would I be okay?

05-06-2017, 03:49 PM	#20
alexusbailey_s13 Leaky Injector Join Date: Jun 2015 Location: Orlando, FL Age: 25 Posts: 79 Trader Rating: (1) Feedback Score: 1 reviews	I have a similar issue going on. My sounds like a binding noise when Im slowing down. It just started today. No matter if Im in gear or in neutral. It seems like its coming from the center console or passenger side when the noise is made. Car - 95 S14 Zenki SR20DE Z32 LSD And other shit.

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