Loud Clunking Noise On Rough Roads

[WingsThree]

Hello everyone, still in “break-in” mode with our new 2018 Aspire 42 DEQ. While we certainly enjoy the smooth ride offered by the air suspension, we are alarmed to occasionally hear a loud, metal on metal clunking sound emanating from the right front portion of the coach when driving over undulating roadways that cause a brief porposing of the coach. The sound is almost always a double clunking sound, in quick succession. Clearly something is "bottoming out" - it's loud and quite unnerving. I have an appointment to take the coach in for a laundry list of stuff that needs working on, but the chassis noise seems to be the most serious. Any thoughts before we go in for the maintenance work? Thanks everyone!

[Mike and Cha]

It's probably your step moving when you hit rough roads, the sound can be pretty loud.

[gbrash]

We heard the same type noise during the worst porpoising we’ve felt coming north on I-5 in California on our 2018 Aspire 44W. For us the noise seemed behind us towards the middle of the coach. No known repercussions from it, but definitely caught our attention.

[WingsThree]

Exactly the same here. It sounds too far aft to be coming from the wheel area. As you say, only during porpoising. It's always a quick double-clunking - it's like a very loud clicking sound. It certainly doesn't sound right - metal on metal, certainly can't be good.

[carcrzy]

I have the same experience. It is the front end. one clunk on compression and a second on the release.

I'm certain that it is not the step.

I took it to a local Spartan repair facility. I demonstrated the noise. They heard it; but they could not locate the origin of the noise.

If anyone gets this diagnosed successfully, I'd definitely like to hear about it.

I have an appointment to take it to Spartan in MI. However, the earliest I could get an appointment, was September.

[brobox]

Here is a list of others some with solution. The Google search bar at the top of the page turned up these posts. https://www.google.com/search?q=Ente...earch=irv2.com
I hope will help your situation, I hate those hard to find noises.

Some of the previous post here have been the rear U bolts not re-torqued at the required 5, 000 miles. Also loose steering components. JME, but Spartan does not do the best job of checking front ends before leaving the factory.

[czeeb]

I had both the porpoising and loud banging when it came back down. The dealer made adjustments to the suspension that resolved the porpoising and discovered that the front door for my generator was not secured and would move around, making the banging. They made some changes to the right side and that noise is now gone completely.

[Rollin101]

If it's the same one I've heard I think it's the front end hitting the travel limits on the bags, shocks, suspension etc.

[mike625]

Originally Posted by carcrzy

I have the same experience. It is the front end. one clunk on compression and a second on the release.

I'm certain that it is not the step.

I took it to a local Spartan repair facility. I demonstrated the noise. They heard it; but they could not locate the origin of the noise.

If anyone gets this diagnosed successfully, I'd definitely like to hear about it.

I have an appointment to take it to Spartan in MI. However, the earliest I could get an appointment, was September.

We have the same thing happening on our 44B we just picked up - it going in next Tuesday - will report back

[Butte64]

Spartan took care of the problem on mine by torque adjustment on control arm pivot bolts and lower eccentric bolts. Also set ride height and verified tire pressures. The new Konis probably help also.

[WingsThree]

Thanks all. Going to National Indoor RV in Phoenix next week. I'l print this thread to help this along. If anyone learns anything more, please chime in!

[777 Driver]

Originally Posted by Butte64

Spartan took care of the problem on mine by torque adjustment on control arm pivot bolts and lower eccentric bolts.

The short version of my story is that my loud clunk when going over a hump in the road significant enough to cause, what seemed to me to be full suspension travel, on my late model 2018 Anthem 42DEQ (produced in late December 2017) was loose lower eccentric bolts on the right front control arm.

Now, for the rest of the story:
The cause of the clunk was discovered during the June 4 - 8 Spartan Academy. I had loose eccentric bolts. The eccentric bolts should be torqued, if I recall correctly, to 425 ft.lbs. Mine were finger tight.

Here's a link to the Reyco Granning manual for the front axle: https://reycogranning.com/rg/wp-cont...09/D711987.pdf The bolts that were loose are depicted on page 12/65 of that document and are depicted as items 3 and 5.

The Spartan tech indicated that the chassis is delivered to Entegra with a rough alignment (all suspension bolts torqued to specs). After Entegra builds the "house" on top of the chassis, Entegra performs a final alignment. Since the build weight and ride height of the house affects the alignment, the final alignment can't be accomplished until after the build is complete.

When we arrived at the Spartan Academy, before the 100 point chassis inspection, the service tech asked if I had any concerns about the chassis. I described the clunk. They discovered the improperly torqued (finger tight) eccentric bolts. At that time, the chassis had about 1,200 miles post-production, pre-delivery to me. Prior to the arrival at the Spartan Academy, I'd put about 3,000 miles on the chassis.

They (Spartan) received authorization from Entegra to complete another ride height adjustment and alignment. In about 2,000 miles since that was done, I've experienced no clunk.

So, on my unit, it seems that the source of the clunk was improperly torqued eccentric bolts on the right control arm.

Take care,
Stu

[Tradition]

Having the same problem with 03 Tradition, replaced king pins, front bushings, and rear control arm tune of 8M and still have same problem.
They retorqued all the front end bolts also.
Could this be an air bag right front issue, coach will pull and dip to the right during panicky braking only, acts normal in hard or normal braking.
Any suggestions would be appreciated

[brobox]

Originally Posted by WingsThree

Thanks all. Going to National Indoor RV in Phoenix next week. I'l print this thread to help this along. If anyone learns anything more, please chime in!

If the problem continues after the visit to NIRVC, as Stu said and my experience, a quality suspension shops is going to have to do their magic. Chassis's leaving the Spartan factory with tight suspension does not always happen.
If there are signs of bottoming out, change the shocks to Koni's. The ride alone, will be worth it.