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1993 240 wagon; I just finished a full mechanical restoration including shocks, bushings, ball joints, inner/outer tie rods, upper spring seats, the works.
I've been struggling with a persistent clunk from the front passenger suspension. It manifests predominantly during acceleration, or turning and accelerating over bumps; when the weight on that wheel is reduced. I generally cannot feel it through the steering wheel, but it sounds exactly like when the top nut on the strut is loose.
It's hard to describe just how many times I've had everything apart for inspection looking for the culprit. I've checked and re-checked that top nut, the shock retainer nut (inside the spring), the ball joint, and all bushings on the control arm. I've checked for any play in the tie rods, and have also checked the wheel bearings for play. I've checked the calipers and disc shield for looseness as well.
In fact, when I jack the car up and start banging on things, I cannot reproduce this clunk. Even when I put some load on the spring to approximate weight, I can't reproduce the sound no matter what I try.
I need a sanity check from the community. Is there a component I forgot to replace during my overhaul that I'm not thinking of that could cause this?
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