Front Suspension Clunk under hard brakes

[djhampson]

My 06 D3 is making a clunking noise from the front left wheel when I brake, but usually only under heavy brakes.

I have just discovered that the ball joints were replaced under warranty by the previous owner at 65k and the car is now at 120k - could they have worn out again? Is there a way to tell if the redesigned ball joints were installed?

Or could it be something else?

It only happens under brakes and I have tried very hard to hear the noise while driving over speed bumps, kurbs, bumps etc but I cannot hear it.

[away]

I had the same thing in my D3. I couldn't convince any Dealer that it was happening (they couldn't reproduce the problem....apparently). Anyway, when I got to Alice Springs, the Dealer there actually spent some time on it and systematically went around and tightened all of the nuts in the entire steering system. He eventually came across a nut in the steering column that he was able to turn about half a turn, and I never had the problem again.

I also had the suspension bushes changed but these exhibited a completely different symptom.

Cheers

Russ

[landyfever]

My 06 D3 is making a clunking noise from the front left wheel when I brake, but usually only under heavy brakes.

I have just discovered that the ball joints were replaced under warranty by the previous owner at 65k and the car is now at 120k - could they have worn out again? Is there a way to tell if the redesigned ball joints were installed?

Or could it be something else?

It only happens under brakes and I have tried very hard to hear the noise while driving over speed bumps, kurbs, bumps etc but I cannot hear it.

That sounds like worn control arm bushes to me, if they haven't be replaced before then they will be very worn by now. Also the balljoints will be worn as well.
Have you tried British Off Road at Forest glen? They are raplacing them with polybushes which are proving to be more durable.