In case it helps anyone else, I fixed a major and consistent clunking/banging noise in the right front of my son's new 81 242 in a few minutes for free. I was following the Tech Tip in the IPD catalog about "200 Series Front End Clunks." I found five bolts on the right side not torqued to specs. The three main culprits were the three that hold the A-Arm rear bushing mount (14mm socket). All three were loose. One wasn't even hand tight, and the other two I could have undone with a socket on a screwdriver handle. Also the two front crossmember bolts on the right side were about a half turn loose. Tightening everything cured the problem. Huge difference.
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Thanks to everyone for the help, Doug C. 81 242 Brick Off Blocks, stock, M46; 86 240, 131k

I tightened up my sway bar link rod bushings, didn't even have to get under the car or jack up either wheel. No more clunking. I love it when life works out this easily. Now if only the electrical glitch in my instrument cluster would be so easy.

Thanks for the tip.

Glad it worked out for you. Those kind of repairs are fun. Now if we could figure out why my son's 81 won't generate any spark from the coil when his coil generates lots of spark when installed on my 81, and my working coil won't generate any spark on his car. Well, we eliminated the coil as the problem, but we don't know where to go from here. Any ideas?
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Thanks to everyone for the help, Doug C. 81 242 Brick Off Blocks, stock, M46; 86 240, 131k

A few people reported clunks on the right hand side, and I guess they have left hand drive models. My right hand drive has a clunk on the left. Perhaps it is a common occurrence on the opposite side of the steering box, perhaps it has to do with being on the passenger side where drivers tend to misjudge the distance to the curb, and where the drains and man holes are. The passenger side probably takes the most punishment.

Thanks for the great tip.

Doug, I've been also having some clunking in the front and saw the tip in the catalog. Been meaning to get to it for some time now. Glad this helped you out. Now I'm more convinced to do check this out on my car... thx! Will let you know how it all works out.
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Michael 'Street'... one AZ '85 244DL 185K miles

Thanks for the heads up. I've got some clunkiness, so I'll check into those things.

Where did you get those tech tips? My google search isn't coming up with anything, and it seems that the IPD site is down. Was this a FAQ list on their site, or was it something you had to buy?

The Tech Tips are in their regular catalogues. Some good ideas.
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Thanks to everyone for the help, Doug C. 81 242 Brick Off Blocks, stock, M46; 86 240, 131k

Thanks for the tip about Tech Tips in the IPD catalog. I'm in Canada, so I balked at their $6 shipping fee, but with the consistent good feedback about their operation and the promise of good info, I caved and ordered one.

In various pages of their website, there are links to pdf's on various topics. Do you know of a comprehensive list of all of these pdf's, so I can download them all?

I don't know, but if you find one, please let me know.
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Thanks to everyone for the help, Doug C. 81 242 Brick Off Blocks, stock, M46; 86 240, 131k

good info,I have a clunking sound on the right side of my auto, was going to look at it today and feel the ball joint and tie rods.
Now going to look at the A-Frame and c-member as well.
THANKS,I enjoy free repairs.
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Kevin * HONDA spanking,1985 240DL * VOLVO ON!!!!

Be very careful with these bolts - they screw into captive nuts, 2 of them inside the chassis box section, and in my experience often rip out the threads when you try and turn them. Whether tightening or undoing, use penetrating oil and ease them very cautiously.

Extremely good point. I hadn't heard that they were particularly susceptible to stripping. IPD says 29 foot pounds torque. Bentley says 30 pounds. Stripping those out would be a pain. Thanks for the tip.
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Thanks to everyone for the help, Doug C. 81 242 Brick Off Blocks, stock, M46; 86 240, 131k

THANKS,good info.
Turns out the clunking im having, is the inner tie rod end.(ZF rack).
Also noticed a leak on the drivers side of the ZF rack,at a pop riveted little plate, a little off center to the rear of the unit."?" don't know whats back there yet or exactly where it's leaking from.
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Kevin * HONDA spanking,1985 240DL * VOLVO ON!!!!