Hey everyone,

My 745 has something wrong in the front end that no one can seem to explain (including me). I have checked the FAQ several times, but it doesn't seem to have tny new ideas for me :( This 'clunk' is driving me INSANE! I bought the car in October '01 at 241K km and as far as I can remember, it's been making the clunk in some form ever since. The frist things to be replaced where the 4 radius rod bushings. They were replaced shortly after I bought the car and where replaced with heavy duty (police and taxi) Volvo bushings. The front shocks were replaced with KYBs just before I bought the car and have been replaced again reciently (to try to cure the clunk). All the swaybar bushings have been replaced with new poly bushings and both front ball joins have been replaced. The 4 remaining original bushings in the lower front appear to all be in good condition. The orignial ZF rack has been replaced with a good use TRW rack which has tight inner and outer tirerods. The upper strut bearings seemed fine the last time the shocks were replaced (a couple months ago) and my mechanic said the upper strut bushings appeared to be fine. I don't know how much longer I can take this clunk. It's most apparent at lower speeds (under 60 kph/40 mph) and over quick, sharp, bumps (lots of potholes around here. I avoid what I can). I can feel the clunk in my left foot when it's resting on the driver's footrest pad. Sometimes when I go over short dips in the road, I hear and feel one single sharp clunk. It's not too loud, but it's certainly there. Occasionally (like tonight), the driver's side will start to squeek which can be reproduced when the car is bounced by hand. The clunks cannot be heard except when driving. My Volvo mechanic and I have examined the front suspension several times and can't find anything wrong. My mechanic says the front end is in excellent condition. The only time I ever remember the clunk being somewhat quiet was after the radius rod bushings were replaced. Even then, the clunk returned to 'normal' after a short period :( Every time a part has been replaced and the problem has seemed to get quieter, it only returns in full force within a few weeks or less. I tried just forgetting about it and ignoring it, but it's just SO annoying. It also really bothers me knowing something isn't the way it should be. Anyway, HELP/advice would be GREATLY appreciated! And, if you have any questions that I haven't answered, just ask. I'd really(!) like to solve this on going problem. Oh, if it matters, the front brakes have been pulsing almost as long as I've had the car as well. I think the front rotors are a little warped. They were replaced along with the calipers just before I bought the car. We've cleaned the hubs, which improved the pulsing a bit. I can't see how this would cause or be related to the clunk. Thanks for any help!
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Chris. Halifax N.S. '91 745Ti, 273K km.