Just bought a pristine 1994 Accord Wagon LX that was owned since new by a little old lady (Really). It has 160K and runs great. There is a slight klunking noise coming from the front end on both sides. I assumed the Ball Joints were bad so I replaced the uppers and throughly checked the lowers... they are OK. The Struts were leaking slightly, so I replaced them. The stabilizer link bushings looked OK but were a little dried out, so I replaced both sides and also replaced the inner stabilizer bushings (body mounts). Checked the radius arm bushings, they are good. Checked the lower control arm bushings, they are good.
I'm at a loss to figure out this noise. It mostly happens when hitting small bumps in the road. It's almost like a rattle, but it is definately in the suspension.

Any guesses?

 

tie rod end links?

 

Yes I checked the tie rod ends, they are also very good.

 

Wheel bearings?

 

I didn't pull the wheel bearings, but I tried to rock the wheel it all directions while the car was jacked up and I even took the weight off the suspension by putting a jack under the lower control arm while the car was jacked up and I rocked the wheel... all seems good and tight.

 

i would also check your spring height. They might be sagging enough to bottom out occasionally?

 

I have a 1990 EX 4D Auto with 302K miles that started that kind of noise around 290K from the passenger side. I had the same theories you did but had front end inspections done. I kept getting the same non-conclusive answer so I pulled the wheels off and shook the suspension in an attempt to reproduce the noise but, no luck. Anyway, I took it to a friends mechanic and it ended up being the strut mount plate/bushings (on top of the strut- mounts the strut to the body- 3 screws). I havent taken this one apart but way back when on my 1973 Civic there were bearings in the mounting plate and these wear (Im told). While he was in there he advised that my upper control arm was shot so I had that done as well. The noise has stopped.

F-Forward to today. The drivers side now makes the noise. Whats weird is that it started doing it after I loosened the center nut on the top of the strut (and retightened it). I decided to replace the clicking CV axles (half shafts) and while in there, the upper BJ/control arm and strut mount plate too. Turns out that the upper BJ was tight with no play so I left it and upon inspection of the mount plate there appear to be no bearings in it so I left it alone too. The only parts replaced were thehalf-shafts and brake pads. The strut never came out or was loosened except the center top nut which I retightened. I looked at the illustrated parts breakdown (IPB) from Honda and it looks like there are only bushings in there. Weird- I would say that my mechanic fibbed but he certainly didnt charge enough to justify the throretically needed repair and I know him quite well- he's not a liar.

So after all that, I have kind of just left it alone and it has actually gotten a lot better without me doing anything which would support the bushings theory. Anyway, I would think its in the strut mount area because little bumps will make the strut chatter on worn rubber bushings. Did you replace them with the struts?

Sorry about the long story... unless you like long stories- Cheers!

 

Wow, what a great reply. I had removed 1 of the stabilizer bushings that connect to the body, but it looked OK so I just rebolted it. I have the new bushings for that, maybe I will just replace them anyway. The noise sounds like a strut bar knocking and not like a ball joint, but I could be wrong.
I have also spoken to a mechanic at work and he said sometimes the lower ball joints will feel OK but it is hard to tell by hand. If the stabilizer bar bushings don't solve the problem, I will replace the lower ball joints next.
I'll let you know what I find.