My final solution to the driveline clunk was to go part time 4wd.
I have trawled through all the very helpful explanations provided by the IH8MUD membership over the past year or so and have attended to or adopted suggestions to resolve the dreaded driveline clunk including all the regularly commented on things. Rebalance and grease driveshafts, replace the pinion bearings, the gearbox mounting bushes, stabiliser bar bushes and drive flanges. All these jobs have marginally reduced the clunk but it was still there. I was resigned to living with the clunk believing that the extreme valve body upgrade in the auto upgrade accentuated the issue.
Last week after two runs on the dyno the transfer case lunched itself. We are making some useful power with all the performance upgrades that have been undertaken over the past few years particularly the Titanium turbo fitted prior to Christmas. Two options were available a new transfer case or a part time kit. There are no new transfer case readily available in NZ and I wasn't keen on a flogged out second hand unit. As fortune would have it there was a Marks part time kit on the shelf at my tune shop Trundles so in she went. I wasn't looking for lower fuel mileage or reduced wear on front drive components but just needed to get mobile. What a revolution in driveability and wonders of wonders no bloody driveline clunk. Heads up folk the transfer case can be a significant contributor to driveline clunks.
I haven't tried to do donuts as yet but it is on the cards once I have done my first 1,000 km and do an oil change on the transfer case.
Not able to drive in 4WD on tarmac anymore but more than happy to resolve my clunk issue.
