Front end thumping noise.

KayLarGo · 11-20-2009, 12:56 PM

I know this issue has popped up several times in the past. We have a 2005 Newmar Mountain Aire sitting on a W-24 (2004) chassis. In the last few months it has developed a very loud popping noise or thump on the right front. You can even feel it on the drivers floor when it happens. It only happens going very slow and turning either direction and going over a dip or drive way area. We had Torklift in Seattle tighten and torque the front spring shackels and bolts in this are and do a really good inspection of shocks, supension etc with no help. After I read a previous thread one case suggested bad weld points where the chassis attaches to the W-24. Just forward of the tire ( outside of the shackel is a welded area. On the right side the whole area is rusted but on the left is nicely painted and good weld bead. I don't see a crack but as it was explained it would be hard to see.

Any thoughts or advice??

DriVer · 11-20-2009, 02:34 PM

Quote:

Originally Posted by KayLarGo

I don't see a crack but as it was explained it would be hard to see.

KayLarGo, It is so annoying to have this type of issue because it could get 2 things time consuming and expensive to diagnose if they can't find anything.

I would expect that if all the chassis components are tight and secure I would agree with your initial comments that a body attachment point maybe the culprit.

I don't expect that if you took your coach to Napanee that they would be able to help you since you are way out of coach warranty at this point.

It was posted here in the past that the stabilizer tube mounted in between the springs developed a crack in the metal and this caused a loud popping noise. Just wondering if they ruled out the stabilizer bar in their diagnostic evaluation?

EngineerMike · 11-20-2009, 03:22 PM

You can usually find this type of problem by following a systematic approach. Sounds like you have taken the first systematic look at suspension parts. Now comes everything else.

Before continuing below, I'd grab the passenger's chair and make sure it is not rocking slightly on its anchor bolts, then check the bolts below.

Then it'll take someone on a creeper a while to grab & shake absolutely every frame & body part, trying to get it to evoke whatever rattle it might. Start w/the front cap. I had a hammering in the front, sounded like front left q'tr panel; but it was a driving light that rattled against the front cap opening. Had friends w/lower body panels that popped their pop-riveted angle fastenings, but swore the pounding sound was a suspension or steering part because of when it was activated. Fact is these coaches twist enough to cause these sorts of breaks and telegraphing of sound in the frame, tire well bulkheads, etc. After the front cap, chose a side and work your way down to past the front tire. Then do the other side. If nothing in the way of body parts, go interior to the body again. If not body parts, back to suspension.

One thing about these annoying noises. Its never nothing. I rode the other day w/a friend who had a noise he had isolated to a large picture window on the PS. While he drove I tried to pinpoint the rattle which was loud and irritating. After checking all parts of the frame, I opened one of the two operable window sections. The noise moved. That gave me a place to zero in. Some more checking and found it was the upper soft plastic molding that holds the sliding pane. I couldn't see anywhere it was improperly seated, but it moved enough to creak & rattle. A shim to tighten it helped the problem somewhat, but finding the exact culprit is the start to a real fix.

KayLarGo · 11-20-2009, 03:45 PM

I don't think we ruled out the stabilizer bar but gave it a good looking at. I think the idea about checking seat bolts etc is a good one. My friend has a coach just like ours only a year newer and he found the seat boats were loose on his. It didn't create a noise but found it in routine tightening. Actually the warranty just ran out in May of this year as we purchased our 05 in May of 06 new and had the 3 year warranty. It was happening on the way back from Phoenix in April but no one has discovered the problem. It has however gotten louder and more consistent. I also have the Brazels CAI system on that side and it might be twisting somehow under stress. The last time we were at Brazel's they took it off and lined it with insulation to deaden some of the extra sound we were having. I will look that over carefully.

Thanks for the replies.

BEBOP · 11-22-2009, 01:21 PM

I had a problem like this in that going over a dip or a raised railroad track I would get a loud pop on the right hand side from the suspension. After several thing were tried they found a bolt about 5/8 or 3/4 diameter sticking out that was catching the side of the spring and then it would slide by and make the pop. there was about over an inch of bold sticking out past the nut so they cut off enough for clearance and end of an aggravating pop that took them most of 2 years to find.

DriVer · 11-22-2009, 01:53 PM

Quote:

Originally Posted by BEBOP

.... there was about over an inch of bold sticking out past the nut so they cut off enough for clearance and end of an aggravating pop that took them most of 2 years to find.

BEBOP, Amazing. You would think that someone would have seen the metal scrapings on the spring where the bolt was striking before 2 years had passed. Bet your glad that's over with.

KayLarGo · 11-22-2009, 04:24 PM

Like Driver says - amazing but an easy fix to an annoying problem. I just hope the chassis doesn't decide to go NW and the body NE some day.

Thanks

BEBOP · 11-22-2009, 05:06 PM

It won't
That bolt should have been an inch shorter. Just another one of many factory screwups on this coach

DriVer · 11-22-2009, 07:16 PM

Quote:

Originally Posted by BEBOP

It won't
That bolt should have been an inch shorter. Just another one of many factory screwups on this coach

BEBOP, Would be intersting to know if it were a coach bolt or chassis bolt? It would be nice to see a picture.

BEBOP · 11-22-2009, 08:05 PM

Next time I bring the coach from storage to the house, I will try to remember to take you a picture. That will probably be right after it is safe to drive again

DriVer · 11-22-2009, 08:08 PM

Quote:

Originally Posted by BEBOP

Next time I bring the coach from storage to the house, I will try to remember to take you a picture.

OK! You're on!

woodyk · 11-23-2009, 11:42 AM

KayLarGo,

I had the exact same thing happen and mine turn out to be the balance weight had come loose and was banging around in the hub cap. When I went faster it of course stayed in one place do to enertia.

WoodyK

KayLarGo · 12-15-2009, 06:25 PM

Good news.

I think my problem has been solved thanks to everyone's thoughts and advise. I inspected everything I could think of. I really didn't see a cause except a possibility of my Brazel's CAI system. Regrettably, I took two actions

as we were to move from North Phoenix to Apache Junction to a different park. I relocated the CAI as I attempted to clean the filter and found it impossible to get to. I also have the Workhorse cooling hoses on for the sparkplug wire heating problem which stopped that problem. The CAI hose to the engine is almost rigid and was under stress in the opening towards the grill. I now have access and can clean it.

I then saw the front stabilizer on the riders side had some bright areas about a quarter of an inch wide from lateral travel as it passes under the bracket. I took out my trusty can of penetrating oil to the stabilizer and the leaves of the springs being careful not to get any on the shackles.

End result - no poping and I went over some pretty sever curb drains while turning at the old location and into our new site. In fact this front end has never been quieter free from rattles etc. My regret is that I took two steps but at least it's fixed. Most people don't have the added CAI system or the workhorse kit and won't be a problem. Thanks for the inputs.