07 S60 - Very low toned clunk - Not Struts

[soulvoid21]

As the title say, 07 S60 2.5T AWD and I have been chasing the most annoying clunk/binding issue for the last year. It's not the struts mounts, I know those are common failure points, both of which have already been changed and only have a couple hundred miles on them. I've also mostly rebuilt the front suspension already including control arms with bushing and ball joints, outer tie rod ends (not inner though), both front wheel bearings, struts with all mounting hardware, and even the front passengers axle. Upper engine and lower trans mounts are both only 2-3 years old. Front brake system has also been completely replaced. New calipers, pads and rotors.. Car also has a fully new, custom exhaust made by my personal mechanic.

When I'm backing out of a parking space, mainly my garage/driveway, I hear this very loud, but also very deep toned bassy clunk from the front end. In the car, the clunk sounds like an exhaust without a resonator is the best way to describe it (I once heard someone describe the sound as a garbage truck outside of your house when referencing exhaust noise. This is similar, but a clunk, not exhaust note). It mostly happens when reversing, but will also happen while the car straightens out after pulling away from a parking space, and happens when going over small bumps/turning. I'm also getting a weird binding feeling when near full steering lock, that feels like spiders gears in an old GM rear end that have gone bad, but this symptom comes and goes. I've always known diffs to either be bad or not, not come and go. On the highway, I also get a vibration at about 70mph that will come and go, but once I hit 80-90mph, it becomes a pretty violent shake, especially while braking.

I've uploaded a video to YouTube where you can hear the noise. It's VERY hard to record/hear through a video, but if you're using a phone and hold it to your ear, you can hear the bass clunk (I can even feel the vibration from the bass on my phone personally).



My mechanic has had this car on the lift 6-8 times trying to sort this problem. Only obvious signs of leaks are the power steering rack (but I have no issue with turning the wheel, or it feeling like it's binding. The binding described above is in regards to forward/reverse motion, not steering.) but no other obvious leaks like from the angle gear. No mounts or bushings appear to be perished. No obvious signs of anything rubbing/hitting. I've even been under the car twice myself while he had it up and cannot spot anything.

I know the Volvo community is the best and we'll find the culprit like we always do!

[dikidera]

It almost sounds muffled I was half expecting a more audible clunk that happens around the gearbox but this is more muffled and not very well defined.

[soulvoid21]

It almost sounds muffled I was half expecting a more audible clunk that happens around the gearbox but this is more muffled and not very well defined.

Right, and that's why we're having such a hard time finding it. Doesn't make the noise either while on the lift.

It definitely sounds like it's coming from the center of the engine bay. Around the passengers axle bearing or angle gear area (which is why we tried changing the axle, plus the one boot was leaking and got antifreeze in it from a failed thermostat housing, and the bearing on the axle was horrible when turned by hand. Axle was definitely bad either way). I'm just dreading the thought of it being the angle gear -_- I know that's a problem point for these cars, but I thought they pretty much nailed it with the 07 model year. My car is one of the last revisions for the P2. I can post the VIN if that would help at all.

[MoVolvos]

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Should have the axle bolt, if so this could be the issue?
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[soulvoid21]

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Should have the axle bolt, if so this could be the issue?
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I had the axles removed from both hubs when doing the suspension work. I'm almost 100% certain they are torqued and not loose, but I will check just to be sure. I know this did happen one time when I first bought the car. Drivers axle bolt was loose, but I was getting a DTSC error since the ABS ring wasn't centered with the sensor. The axle was pushing itself out of the hub. I will triple check tonight though.

I want to note though that the sound is not coming from the wheel hub/axle area. It sounds like it's coming from the center of the engine bay, directly behind the center console in the car, maybe more towards the passengers side.

[soulvoid21]

As expected, the axle bolts on both sides are definitely seated properly. This noise is also not a metallic sound. To me, it sounds like bushing that has completely let go, and it just slopping around, but only while turning.

I also just double checked what bushing I could while the car is on the ground, and all seem fine.

[June]

Have you checked the frame bushings yet? It's a known problem and some models had a recall. Volvo made updated bushings for those P2 cars. I had mine replaced on my 04 S80 around 160K. My car had some of the same symptoms. Be aware the bolts are torque to yield, so must be replaced. My car also had the issue of the steering binding one way, chunks, thumps, bangs, and as things got worse unstable alignment on the interstate. When the frame moves it shifts out of alignment causing the steering problem.

I asked my dealership endlessly it seemed to fix those problems. Finally around 160K the rear main engine seal went and the frame was removed. Three of the four bushings simply fell out as the frame was lowered to the floor. Even then I had to insist on their replacement... afterward was night and day difference. June

[soulvoid21]

Have you checked the frame bushings yet? It's a known problem and some models had a recall. Volvo made updated bushings for those P2 cars. I had mine replaced on my 04 S80 around 160K. My car had some of the same symptoms. Be aware the bolts are torque to yield, so must be replaced. My car also had the issue of the steering binding one way, chunks, thumps, bangs, and as things got worse unstable alignment on the interstate. When the frame moves it shifts out of alignment causing the steering problem.

I asked my dealership endlessly it seemed to fix those problems. Finally around 160K the rear main engine seal went and the frame was removed. Three of the four bushings simply fell out as the frame was lowered to the floor. Even then I had to insist on their replacement... afterward was night and day difference. June

I'm thinking it's the subframe bushing, or the inner tie rod. I was just outside messing around and the only possible items in the location of the sound is inner tie rod, steering rack, subframe bushing or the AWD diff. I'm banking on subframe or tie rod.

Worth noting, I did have the trans swapped about 30k miles ago. Long story short, PO maintained everything but the trans.. every gear slipped and you could smell the trans fluid burning going up hill. Got a used junkyard unit and it's been fine ever since. But my mechanic didn't mention anything about the subframe bushing when he did this job. But at 173k miles, I'm sure they're old and crusty.

I'm going to order a set of inner tie rods and frame bushing from FCP, since it would just be a good idea to replace them anyway (money was tight when I first replaced the other suspension components). I do have a slight alignment problem where it'll pull to the left (mostly) but after driving for a bit it sort of shifts around. It won't pull at all, then it will. Bushing makes sense in that case.

[June]

Remember to replace the bolts! They are one time use only per Volvo. The bushings are pressed on to the frame. My dealer sent my car's frame out to a machine shop. Personally I would only use Genuine Volvo bushings. June

[Blacklab467]

Yes, only buy Volvo brand bushings and bolts, they are reasonably priced compared to aftermarket and infinitely superior! Also if all the other parts you replaced chasing this problem we’re cheap aftermarket parts you may be back where you started, I was initially going to suggest strut spring mounts with regard to your clunking, or strut bearings.