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Old 04-15-2015, 07:53 PM   #1
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Help I have a large rattling /klunking noise on the right side.

I have a 2015 Canyon Star 3921 that in the last 400 miles a loud clunking/rattling noise appeared somewhere around the passenger front tire in the area under the passenger seat. When I hit bumps or apply and release the brake rappidly I hear this noise almost like a suspension clunk / rattle in a stabilizer link or something like that. We went through the underneath with a fine tooth comb including hanging the suspension,checking kingpins banging on the tire with a large mallet and cannot find anything. It is very evident and is worrying me because we are leaving in a few days for a 1500 mile trip. I would appreciate any suggestions or solutions that may have occurred with your coach thank you in advance.
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Old 04-15-2015, 08:10 PM   #2
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Did you check the sway bar carefully....a lot f times the bushing will come out where it "U" bolts to the frame in two places?

Could it be a broken shock?

Mines a diesel, but I had a clunk when new and it was the steering box bolts were all loose.....just some ideas.
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Old 04-15-2015, 08:15 PM   #3
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Do you have sliding trays in the basement thst may not be latching?
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Old 04-15-2015, 08:43 PM   #4
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On the Workhorse chassis the spring suspension to the rear attachment use to need a plastic shim in between the two springs would make the wife jump every time it clunked when spring collided, I know you have a Ford but Fords new chassis suspension is almost like the old WH chassis.
Discussion of shims.
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Old 04-16-2015, 05:58 AM   #5
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We chased a similar situation toward the rear of our 2013 CS for the better part of a year. Some dealer techs discovered one bolt, a single bolt, that was not torqued down and it allowed micro movement of the component it was attached to .....all of which translated to a definite "clunk" every time there was any force exerted on it. As a precaution they checked under the entire Ford chassis and found that the tops of the front shocks had also loosened up. I had been under there several times and everything looked OK to me. But, hey, what do I know? While I'm generally mechanically inclined I'll be the first to admit I'm not a trained mechanic. As a suggestion you may want to get another set of eyes to check out your chassis nuts and bolts. BTW...I see you are in Massachusetts. Did you buy from Diamond RV? We used to live in New England and had stopped there on a number of occasions to look at their Newmar's. Good luck finding the noise. Keep looking. You'll find it and hopefully it won't be a true safety issue.
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Old 04-16-2015, 06:00 AM   #6
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I do not have slide out trays and yes purchased at Diamond RV.
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Old 04-16-2015, 06:08 AM   #7
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Quote:
Originally Posted by LongDogRanch View Post
We chased a similar situation toward the rear of our 2013 CS for the better part of a year. Some dealer techs discovered one bolt, a single bolt, that was not torqued down and it allowed micro movement of the component it was attached to .....all of which translated to a definite "clunk" every time there was any force exerted on it. As a precaution they checked under the entire Ford chassis and found that the tops of the front shocks had also loosened up. I had been under there several times and everything looked OK to me. But, hey, what do I know? While I'm generally mechanically inclined I'll be the first to admit I'm not a trained mechanic. As a suggestion you may want to get another set of eyes to check out your chassis nuts and bolts. BTW...I see you are in Massachusetts. Did you buy from Diamond RV? We used to live in New England and had stopped there on a number of occasions to look at their Newmar's. Good luck finding the noise. Keep looking. You'll find it and hopefully it won't be a true safety issue.
X100, Torque upper shock bolts! If you don't have a torque wrench get a 1/2" breaker bar and tighten as tight as you can get. I would almost guarantee it will cure your rattle. Do both sides. I just went through the same thing on a brand new coach. Upper shock bolts not torqued to spec but lower are, go figure.
PS: Dry torque is over 300 lbs so I doubt you will get that much on it but I bet you can get close to 200 and that will stop the clunk. Remember the KISS theory,
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Old 04-16-2015, 06:19 AM   #8
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Tell the DW to quit shaking her head. On second thought maybe you better not!!
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Old 04-16-2015, 07:07 AM   #9
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My right front tire mud flap was loose and created a lot of noise, Good Luck
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Old 04-16-2015, 10:54 AM   #10
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Thanks To All

All the shock bolts were lose except one shock in the rear. It sounds and rides like a different coach.
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Old 04-16-2015, 11:11 AM   #11
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All the shock bolts were lose except one shock in the rear. It sounds and rides like a different coach.
Awesome! Hard to believe something so simple can cause so much grief!
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Old 04-16-2015, 11:20 AM   #12
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Very happy for you that you found the source of the noise. These are great machines when things are going well. But as soon as something changes it has a tendency to get a lot of attention. So much more pleasant going down the road when the noises are few and far between.
Safe travels!
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