I have a 2009 HHR that developed some pretty good clunking noises in the front end. Discovered the lower control arm bushings were shot so i replaced both lower control arms with new one that came with the new bushing and ball joints. It was an easy swap. Clunking still there.

Next i replaced the whole strut assemblies with OEM struts, coils and mounts and insulators but to my dismay the clunking was still there. AFter that i replaced sway bar bushings and links and it's still clunking. Last thing i did was replace tie rod ends but that didn't stop the clunking either.

I can say it's not coming from the steering shaft, it's something in suspension can feel it kind of in the floor boards both sides. Everything is torqued to factory specs. I checked rack and pinion bushings and they do not appear to be the problem as i can not get any play when prying with a pry bar. Hub bearings replaced about a year ago with Moog hubs so it's not those.

There is nothing left to replace so what in the heck is clunking?? It's driving me insane that i can not find this. I do not see any metal to metal rubbing anywhere on the suspension. Only thing i really noticed was when car is jacked up i can get about 1-2mm of play in the ball joint where it mounts onto the knuckle and pushing/pulling up down motion. I was given right parts. Not the best ones but i got them at auto zone. specs say for FE1/FE3 suspension which i have.

I kept my original control arms and had a mechanic i know press the OEM bearings out and new ones in. I have seriously considered putting the factory ones back on since all that was wrong with them were the bushings which have been replaced now. those still have the original ball joints on them which are in great shape. I'm curious if the duralast control arms are what's causing the clunking. Also wondering if i got a defective set of struts because this car sounds like the front end is going to fall off when i go over bumps.

What is the problem here?

 

Could be the Duralast control arms. I have found that Duralast items are really not all that well made or re-manufactured in some cases.

 

I was thinking that too, but then i got to thinking, what would be making it clunk. the bushings are new. the ball joints are new.unless that control arm is moving around down there somehow. it does have the split rubber bushing on it. The OEM ones i got from amazon are solid rubber all the way around. might just go ahead and throw ball joints on the factory arms since they are off, even though the ones on don't look bad.

Can anyone tell me where i can get rack and pinion bushings? i checked all the typical parts stores and no listing for it. not on rockauto either.

 

FYI- put the OEM control arms back on and no more clunking. I checked the width of the ball joint on the duralast control arms and it is just a fraction of probably a millimeter smaller than the stock ball joints on the original control arms. I did not have access to a micrometer so i used and adjustable wrench and adjusted to the factory one and then put it over the duralast one and there is definately some slight play. Lesson learned!! I know better than to buy aftermarket and i was in a pinch and autozone had them. NEVER AGAIN!! I spent money on parts i probably didn't have to replace trying to fix this issue. I would have never suspected the new parts from autozone. Taking them back tonight and they had better refund them under warranty!

 

I have the same exact problem except with me I have the original control arms still on with new lower arm bushings. Did you change the upper as well by chance?? I'm wondering If my front end is knocking due to the upper bushings not being changed out

 

check your engine mounts