Chasing a new clunk

[Island_Moose]

My 2008 Puma starting clunking after a long trip. I found a perished bushing in the rear sway bar end, and with a new one in place, the loud clunk went away and all I had was normal driveline slack.
Still, I also decided to install TerraFirma drive flanges on all 4 corners. This helped a bit too to reduce that clunk when changing gears.

All was going well until today. Now I’ve developed a noise coming from just a little bit behind the cubby box, it’s a metallic clunk/clank when I let the clutch out, push it in, or get on and off the throttle (mainly in 3rd gear at about 50kph).

Getting under the vehicle, I’ve inspected bushings, mounts, confirmed that both propshafts still have the same rotational play, and the hand brake seems normal.

I can’t replicate the noise in the garage. If I apply the handbrake and rock the vehicle back and forth by hand I hear a slight bang come form somewhere near the rear axle from time to time...figuring that not good I stopped that.

Something wearing out wouldn’t just start suddenly? It’s got me beat...I REALLY don’t want to take it to the dealer...

[Island_Moose]

Why I think it’s a bushing...

If I slow down to walking pace, with the gearbox in neutral (coasting) and apply the brakes hard, I can make it clunk. It can be felt throughout the chassis.

How can you assess the condition of the a-frame ball joint? It looks fine...pry bar?

[Tombie]

Check upper arms on rear diff tension.
Check bolts on brake drum.

[DazzaTD5]

*70K or more, have you had the adapter shaft done yet? If not, it will fail soon and the clunk will stop.
*When you did the drive flanges, did you replace the rear axles as a set? They are soft compared to axles of old and flog out.
*Any diff whine? and does it have much back lash.

*Oh a 2.4lt, has the clutch been replaced yet? if its developed the idle rattle, its on its way out.

[PAT303]

*70K or more, have you had the adapter shaft done yet? If not, it will fail soon and the clunk will stop.
*When you did the drive flanges, did you replace the rear axles as a set? They are soft compared to axles of old and flog out.
*Any diff whine? and does it have much back lash.

*Oh a 2.4lt, has the clutch been replaced yet? if its developed the idle rattle, its on its way out.

First one twice,the second time by me because the first time it wasn't done properly,second one once by me,negative on the third,fourth one twice,second time by me because the first time it wasn't done properly.My vehicle is clunk free at 170K. Pat

[LesDef]

Gidday Island_Moose,

Recently while installing exhaust wrap I noticed the hook of the exhaust hanger in front of the centre muffler was very close to the classic bracket.
Using a large adjustable wrench I bent part of the bracket to obtain more clearance.
Check all the exhaust pipe for clearances.

Regs Lesdef

[Island_Moose]

*70K or more, have you had the adapter shaft done yet? If not, it will fail soon and the clunk will stop.
*When you did the drive flanges, did you replace the rear axles as a set? They are soft compared to axles of old and flog out.
*Any diff whine? and does it have much back lash.

*Oh a 2.4lt, has the clutch been replaced yet? if its developed the idle rattle, its on its way out.

There's no evidence in the service records that the adaptor shaft has ever been replaced.

When I did the drive flanges, I inspected both ends of the half shafts and they seemed untouched so I just put them back in.

No the diff doesn't whine, the back lash has been described as "normal" by other owners.

I'm going to crawl under and look for corrosion coming from the transmission housing.

[PAT303]

Mine gave no clue it was about to fail until it actually did,just a slight knock a few days leading up to it and then it stripped.I'd pull the gearbox and replace both the clutch with a LUK replacement,change the adapter after packing it with grease,and change the trans input shaft seal with a labyrinth seal and run sealant between the gearbox to extension housing,and extension housing to transfer and pack the end of the transfer shaft to transfer housing. Pat