Front End Thumping Noise

[Floridakamper]

I've been searching this forum for info related to my current problem. I've been occassionally hearing a load thumping, crunching noise which sounds like it's coming from under the passenger seat. It happens at slow speeds, on uneven roads. I found info about the shims in the leaf springs and one reference where Driver mentioned a broken weld at the frame. He also said it sometimes causes windshield issues. Thank you Driver. I checked this morning and where the front cap attaches to the frame, the weld is broken. I intend to get a mobile welder to do the fix. It does not look like a big deal. Do I need to disconnect the negative battery cables on the house and chassis battery before the welding? I'll try to load a pic of the failed weld. This has been driving me crazy for six months.

[DriVer]

Quote:

Originally Posted by Floridakamper Do I need to disconnect the negative battery cables on the house and chassis battery before the welding? I'll try to load a pic of the failed weld. This has been driving me crazy for six months.

I might do that. Won't hurt anything.

[Floridakamper]

I also read that Allison recommends disconnection their ECM. I guess that's located on the tranny? Hopefully this repair solves my windshield issues as well.

[DriVer]

Quote:

Originally Posted by Floridakamper I also read that Allison recommends disconnection their ECM. I guess that's located on the tranny? Hopefully this repair solves my windshield issues as well.

Floridakamper, The transmission computer, TCM, is stacked on the ECM, and is located over the top of the radiator just behind the air dam.

[Floridakamper]

Thanks Driver. Looking at the weld again today, it doesn't look like the weld failed, it looks like it ripped the piece out from the piece it was welded to....if that makes any sense.

[DriVer]

Quote:

Originally Posted by Floridakamper Thanks Driver. Looking at the weld again today, it doesn't look like the weld failed, it looks like it ripped the piece out from the piece it was welded to....if that makes any sense.

That makes a lot of sense, the weld held but you experienced metal fatigue and apparently failure of the component. A good welder should be able to repair this. One could speculate as to why this was a point of failure however my best guess would be that the box either became out of square or it might not have been perfectly squared at the time of manufacture. I would also have the repair technician examine the box points of attachment to the rail to make sure it all looks good. A fastener missing on the opposite corner might have caused the failure.

[Floridakamper]

Thurday, a welder came to my home and repaired the failed front cap attachment point. Friday, on this forum I discovered another Kountry Star owner who had the same noise in 2005. With the help of this forum I was able to contact that individual. As Driver said, a box attachment point of the same side had also failed in his case. I examined mine and had the same failure. The welder returned today and repaired that point. I don't think I could be an RV owner without the help I get in the forums. Thank you. Next issue will be the AC compressor. A subject for another thread and another day.

[MNRVr]

It looks like I have the same situation on my 2004 Scottsdale Workhorse. I also get a loud clunking noise during some turns.
Now I guess I need to find a welder that can do the job.
This forum has been a lot of help.
Thanks to everyone that participates.