Still looking for help,
I resorted to bring my car to a Volvo Dealer in De.
The mechanic drove with me a heard the noise many times. I could tell after he heard how loud it was he seemed confident he could fix it. Well, after several hours in the shop they could not find the problem. He was perplexed and asked me to bring it back another day. The first email describes all of the parts replaced. The Volvo dealer also re-checked all of the torque setting on rear suspension parts. I love my 240 but I m ready to let it go. The car is in great shape all conceivable parts replaced in the rear but cannot find the problem. Could a tire make a clunking noise? It sounds like the 1st muffler hitting the floor but further back.
Any ideas??????





1988 240 102k miles
I have a banging/thumping noise on the passenger side in the rear of the car when I go over a bump or pot hole. The noise seems to be the exhaust system. I replaced the exhaust with a under axel, replaced all 10 bushings in the rear, transmission and engine mounts, shocks, drive shaft bushing and muffler hangers. If I am traveling at a higher speed and the bump is small then there isn't a thump. I have about 2.75" between my axel and muffler pipe. I also checked my rear wheel bearings, no issue. The only thing left that I think that it may be is the new catalytic converter (Volvo part) has a floating flange and may undulate when the engine moves on the mounts. When I purchased the car it had the new converter. The other theory is the transmission mounts are after market and may be softer than original equipment (long shot). I am running out of ideas any help would be appreciated. Thank you