Guess where my clunk was coming from?

[Ample]

Since I bought this car it has had an annoying clunk which had progressively gotten worse.

The 1st time I really noticed it was when I was reversing out on a steep slope (exit to an underground car park). I thought damn - this sounds like something in my gearbox.

We initially checked the rear arms and replaced all 4 bushes. Still the clunk continued. Last week I thought I'm going to go to whatever extent to find it. So, we checked the front brakes - and that was good - because my pads were a bit low - so we replaced the front pads. Still the clunk continued...

So we checked all the bushes under the car and replaced the 2 bushes on the rear control arm and 3 bushes on the front caster arms.

Still the clunk continued...

Since we had replaced all 4 shocks 2 weeks back, we then checked all the shocks and springs. The rubber circular piece on which the spring sits was missing... and there were marks to prove that metal was rubbing against metal. So in true Kenyan fashion... we cut up a rubber hose pipe and threaded it through the section of spring where it was rubbing.

Still the clunk continued...

We checked the CV's. All okay there.

We checked the exhaust mountings... all okay there.

We checked if my rear fabricated bumper ends were loose and rubbing against any metal or any part of the body... all good here.

We removed the protective cover around the fuel tank.

Still the clunk continued....

Has anyone guessed where it was?

While I drove the car back and forth...my mechanic had his ear to the floor of the car. He then stood outside as I drove past him - to the left, to the right asked me to drive slow, fast, brake hard, brake soft...

In the end we all went home almost giving up.

Next day my mechanic came back and said... "This has really bugged me... I haven't been able to sleep".

We went through the process of driving fast, slow, listening, etc, etc.

He removed the entire fuel tank after emptying the fuel.

VOILA... as we moved the tank we could tell there was something loose inside it.

SABOTAGE? That was my 1st thought.

We opened the top of the fuel tank and the metal waffle plate which keeps the fuel from swishing around too much had come apart.

See the pics ... (the 2nd pic shows the waffle plate).

The 3rd pic shows where the tab had broken.

We decided to cut the top section of the tank, and had the metal plate welded back into position. The tank was then thoroughly cleaned and fitted back to the car (with it's protective cover in place).

What a lot of peace... it has taken us 6 months to get to this fault and about 3 different mechanics have had a shot at finding the place.

I am super happy to have a silent car without any clunks.

 

[rolliges]

Nice work. Never give up. I also have a clunk to find.

 

[Kernal]

Ample: which year, make, model vehicle is this? FWIW and IIRC Toyota had a recall for this problem in ?some model Landcruiser years ago, the parts experts would know the years/models involved.

 

[Ample]

Ample: which year, make, model vehicle is this? FWIW and IIRC Toyota had a recall for this problem in ?some model Landcruiser years ago, the parts experts would know the years/models involved.

This is a 1991 HZJ80. Knowing how things work here in Kenya I would not be surprised if this recall was not heard of here.

 

[chui]

hi - im in kenya as well and having the same issues with this clunk - especially on corrugated roads - have narrowed it down to the body bushes - but getting them xtremely difficult - anyways lets see

 

[jamisobe]

Here it is. It just popped up on the first page... haha

 

[Honger]

I've an FZJ80 and I'm in the UAE... and I have the exact same problem.
With all the pick-n-pull yards around here I think I'm just going to replace the tank.

 

[Ample]

hi - im in kenya as well and having the same issues with this clunk - especially on corrugated roads - have narrowed it down to the body bushes - but getting them xtremely difficult - anyways lets see

As far as I know - you will not get those body bushes from a local source... but where there's a will there's a way!

The majority of the safari LC's and Nissan Urvans have the same issue. The rubber body mounts are fashioned out of heavy duty tractor / Caterpillar tyres by local artisans. They will definitely not be a precision part but from what I have been told they will outlast the factory ones.

If you want these locally fashioned ones let me know and I'll put you in touch with someone who can help you out.

 

[chui]

Hi and thanks for your reply.
We call them masai bushes and I am using them on two of my safari cruisers. I managed to get the bushes from Msa.
But I am still having issues with the undercarriage noise on corrugated uneven roads. I feel its the exhaust hitting the chasssis or something of the sort. Almost defeated as I have got chassis checked, front diff/spline checked, transfer mountings, engine mountings, exhaust and nothing. But alas the fight will go on...

 

[Ample]

Hi and thanks for your reply.
We call them masai bushes and I am using them on two of my safari cruisers. I managed to get the bushes from Msa.
But I am still having issues with the undercarriage noise on corrugated uneven roads. I feel its the exhaust hitting the chasssis or something of the sort. Almost defeated as I have got chassis checked, front diff/spline checked, transfer mountings, engine mountings, exhaust and nothing. But alas the fight will go on...

I can put you in touch with a real good mechanic if you want someone to check it out for you. He also does a lot of work on the Micato safari Landcruisers. Let me know...

 

[chui]

Hi and thanks - will really appreciate that - My mech I have sent to mara to bring back one of the cruisers (half shaft issue) so I am around in Nai this week. please drop me a line on info@zenosafaris.com
thanks

 

[Ample]

Hi and thanks - will really appreciate that - My mech I have sent to mara to bring back one of the cruisers (half shaft issue) so I am around in Nai this week. please drop me a line on info@zenosafaris.com
thanks

Ok - just emailed you. BTW are you running your own camp in the Mara?

 

[djsherif]

Hi Ample,

I think I may have the same issue in my 91 hdj but not sure. The clunk is very intermittent and happens even going 2km/h. The only reason I think it's possibly the same issue as you is that recently I hear the sound of fluid moving too. I already have my rocker panel plugs out and there's nothing in there so I suspect it maybe this waffle thing. Can you tell if it's broken simply by opening the top trap door of the tank?

Thanks.

 

[wrongway around]

Ha good find. I had the same noise but only going up hill, then after some frustrating times my gas gauge would not go past 3/4 . Upon checking float in the tank I noticed the baffle a little to close . Managed to feel around and found it was broken on one side. I bent it clear and wired it back with some stainless piano wire,and problem solved . Its been a couple years now and no probs,a bit get to but whatever. Oh and did it in the truck no removal.

 

[djsherif]

I'm guessing this requires removing the rear seats. Is that correct?

 

[fvaleur]

Yea, rear seats out, and pull back the carpet. The access plate is fairly obvious, and iirc big enough that could easily put your hand down there to check it out.

 

[djsherif]

Is the broken piece in question reachable to fix or tie down from the trap door or do I have to drop the tank?

 

[wrongway around]

I removed seats and was able to do everything through the float gauge door opening . Mine was still attached at the bottom ,I just bent the top clear of the float(bent the baffle to the back) and if you use a mirror and flash light you can see where you can rap the wire around on the inside of the main part of the tank, then ran it through one of the holes in the baffle that lined up close to each other when the baffle was push back. Not much room ,and you have to remember by feel after you sauce it out with the mirror. Good luck pretty frustrating but no easier if you remove the tank.

 

[djsherif]

Thanks I'll see what I can do. If the baffle breaks off or is removed is that trouble?

 

[wrongway around]

Mine was still attached at the bottom . Don't know the answer,sorry . If its completely seperated I think your into the jungle fix . I think its only to control a tidal wave affect from screwing the float gauge arm?...