Like the title says, I changed my ball joints today (fun times chiseling out 17 yr old rivets), now when I move the wheel in either direction sharply (like if I am getting off an exit or a u-turn) I get this clunk. And that'* exactly what its is "CLUNK!". Any ideas? My Lincoln has always made the clunk noise, but this is a first for my Park Ave. I should note we had a hell of a time getting them both on and off. Took it on the parkway and aside from the alignment being messed up and the clunk everything seems fine tomorrow morning i'm getting an alignment and new tires at the stealership (they price match tire rack, and give a free 4 wheel alignment so I guess I can't complain too much!) So ya any one got any clues?



<---- Me busting those rivets!

Is it when you hit a bump? It could be some bushings getting worn out. Does the noise come from the back or the front?

First thing I would check is the sway bar and the end links.

I would raise the wheel and shake the tire

I just did a 100 mile round trip out to West Jersey down Rte 70 (pretty bumpy road) with the radio and air off to listen for this noise.

@2K2SE: On bumps its quiet. All the bushings were fine. Not cracked or dried out. And the noise comes from the front left side. Its like I have a little gremlin under the car and hes knocking the frame. I can feel this clunk.

@Danthurs: New sway bar and end links

@Nighthwk12: Did that. No noise.

Eh, I guess I'll see if the alignment fixes it. Long day time for bed.

Did you look at the spring and strut? Maybe something isn't right, like a cracked spring.. Its strange how you don't notice it on the bumps, only on the flat pavement. There might also be some slop somewhere in the steering. Have you tried turning the wheels left to right while the car was sitting still?

This could help!
A new TSB was issued on 3/27/08. This does include a new designed ISS. The number is 19179923. The TSB is 01-02-32-001O

#01-02-32-001O: Clunk Felt/Noise Heard From Stering Column, Steering Gear and/or Front of Vehicle During Turnign Maneuver and/or Steering Wheel Rotation (Replace Intermediate Shaft As Directed) - (Mar 27, 200

Models:2001-2004 Buick Regal
2005-2007 Buick Allure (Canada Only), LaCrosse
2000-2008 Chevrolet Impala
2000-2007 Chevrolet Monte Carlo
1998-2002 Oldsmobile Intrigue
2004-2007 Pontiac Grand Prix

This bulletin is being revised to provide new I-shaft part numbers for servicing Allure and LaCrosse vehicles built PRIOR to January 1, 2006. A Corrective Action Summary has been added to this bulletin for quick reference. Please discard Corporate Bulletin Number 01-02-32-001N (Section 02 -- Steering).
Corrective Action Summary:

Model Year
Vehicle Line
Corrective Action
2001-2004
Buick Regal
Replace using P/N 19179922
2005-2006
Buick Allure/LaCrosse
(built PRIOR to January 1, 2006)
Replace using P/N 25829292
2006-2007
Buick Allure/LaCrosse
(built AFTER to January 1, 2006)
Replace using P/N 25828562
2000-2005
Chevrolet Impala
Replace using P/N 19179923
2006-2008
Chevrolet Impala
Replace using P/N 25913681
2000-2005
Chevrolet Monte Carlo
Replace using P/N 19179922
2006-2007
Chevrolet Monte Carlo
Replace using P/N 25913680
1998-2002
Oldsmobile Intrigue
Replace using P/N 19179922
2004-2008
Pontiac Grand Prix
Replace using P/N 25913680
Condition

Some customers may comment on a clunk type noise coming from the front of the vehicle while driving during a turning maneuver. This condition may also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Some vehicles may only exhibit the noise once for every 360° of wheel rotation. On all other vehicles, this clunk noise will be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel or when applying/releasing the brakes.
Cause

This condition may be caused by a "slip stick" condition resulting in the clunk noise or feel through the steering wheel.
Diagnostic Tip

Important: This condition is commonly misdiagnosed as originating in the steering gear and has resulted in the replacement of numerous steering gears without correcting the concern.
Attempt to duplicate the customer'* concern and isolate the I-shaft by following the procedure below:
Locate a large area (parking lot) where the vehicle can be turned in a tight circle. Turn the steering wheel to the right and/or left all the way to the steering lock, then off the steering lock a 1/4 turn. Drive the vehicle approximately 5 km/h (3 mph) in a circle, preferably over rough pavement or seams on the road surface. If a clunk is felt in the steering wheel, the MOST likely cause is the I-shaft -- not the steering gear. Continue with the correction.
Drive the vehicle straight ahead at idle speed while applying and releasing the brake pedal. Listen/feel the steering wheel for the clunk-/noise condition.
Correction

DO THIS
DON'T DO THIS
Replace the intermediate shaft
DO NOT lube the intermediate shaft.
Replace the existing intermediate shaft using the service procedure found in Service Information.
Parts Information

Part Number
Description
19179922
Shaft -- Steering Gear Coupling
'01-'04 Buick Regal
'00-'05 Chev Monte Carlo
'98-'02 Olds Intrigue
19179923
Shaft -- Steering Gear Coupling
'00-'05 Chev Impala
25913680
Shaft -- Steering Gear Coupling
'06-'07 Chev Monte Carlo
'04-'08 Pont Grand Prix
25913681
Shaft -- Steering Gear Coupling
'06-'08 Chev Impala
25829292
Shaft -- Steering Gear Coupling '05-'06 Buick Allure and LaCrosse vehicles built PRIOR to January 1, 2006
25828562
Shaft -- Steering Gear Coupling ’06-'07 Buick Allure and LaCrosse vehicles built AFTER January 1, 2006
Warranty Information

For vehicles repaired under warranty, use:
Labor Operation
Description
Labor Time
E7700
Shaft, Steering Intermediate - R&R
Use Published Labor Operation Time

If you didn't have a clunk before hand, then it'* time to look over the area where you worked. Make sure that when you put the car back on the ground, something didn't settle or a pinched bolt that appeared to be tight didn't come free and needs more tightening. As well, a ball joint is a tapered piece. If it sat further into the knuckle and the nut is now not tight to the top of the joint, you can and will get a clunk. This is part of the reason behind having a cotter pin on the nut. So that if something does loosen, it won't come apart.

I'm put it back in the air and double check everything that you did yesterday to ensure settling etc didn't occur.

GTA he is working on a 94 Park Ave. If you wanted I'm in North Middletown. It'* kind of a trip but if you wanted to stop by I could check it out.

I was in Ocean Twp. all day. I'm busy until next week, but that would be good.

The alignment fixed the clunk slightly.