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Old 06-28-2016, 10:01 AM   #1
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Chassis (or not) clunk I just can't find...

We have a 2002 Damon Intruder 350. W22, 8.1, Allison and all the bells an whistles. We love the coach and have put a lot in to it since buying it last October with only 31,000 miles on the clock. Lately it has developed a solid "clunk" when making slow left hand turns. Whatever it is, it's pretty solid and heavy sounding. I have checked shocks and the entire chassis for tightness and nothing is loose. The spring separator pads are all installed in the leaf springs and tight. Everything is properly greased. I'm pretty much at my wit's end on this thing because I just don't see anything loose, nor do I see any wear marks anywhere of something hitting something. I don't feel the clunk through the steering wheel at all, but I feel it SOLIDLY through my feet, like it's hitting the floor board?

I found my drivers side front leveling jack was loose and tightened it up, but still the clunk remains. I've lurked through every thread I can find on here and have read about broken welds, but have only found info on Ford chassis with that problem.

I'm truly stumped here. Has anyone run across a similar problem in the Workhorse W22 / Damon Intruder coach??
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Old 06-28-2016, 10:31 AM   #2
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probably a worn out bushing. Have a truck shop swap them out for you and I bet that clunk goes away.
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Old 06-28-2016, 10:33 AM   #3
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here's another , similar post, where they speak of replacing a nylon spacer..

Front End (Clunk) noise
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Old 06-28-2016, 10:35 AM   #4
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and another where they found a weld had come loose, gotta make it through the first 8 posts or so up until where he identifies it's a workhorse chassis.

RV.Net Open Roads Forum: New Noise! Thump/Clunk over right front Wheel Well

someone in this thread also mentioned that they had all bolts tightened at a shop and the mysterious clunk mysteriously went away
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Old 06-28-2016, 10:57 AM   #5
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Clunking could be the front bushing of the leaf springs, look and see if you see any gaps or wear spots.

Spray them with a grease and see if the intensity of the clunk changes. Maybe you can find what's moving.

Of more concern, would the Ubolts, holding the axle to the springs. There should not be any movement there.

Also watch the steering box while someone turns the wheel. It could be loose.
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Old 06-28-2016, 01:21 PM   #6
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Thanks for the ideas. Spring bushings look good and tight and all ubolts are tight to spec. Trac bar is tight and has good urethane bushings, Safe T Steer is tight.

I'll check the steering box tonight. Hadn't thought of that one! But like I say, I don't feel it through the wheel at all, just the floor. Sure won't hurt to look though. This thing is driving me mad....
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Old 06-28-2016, 08:45 PM   #7
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UPDATE!!!

Truth being stranger than fiction, it was a leveling jack. The springs are apparently still strong enough to retract the jack, but not strong enough to pull it into locked position!!! The jacks are tied together, so when the PASSENGER SIDE jack would flop against its mount, I felt the clunk under my seat. The wife sat in it while I jiggled the jack, and sure enough, there was our noise!!!

Ordering new springs and laughing. Thanks for all the quick replies!!!
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