This should not be such a mystery. I am still trying to fix it. Replaced 2 struts, 2 top rotating bearing plates, 2 sway bar links, 2 lower control arm bushings, just one axle. All that is left is one more axle ane 2 sway bar bushings. any thoughts? Front end is almost all new.

 

HHR~SS~Panel,

Let me know how everything goes!

Thanks,

Evan, Chevrolet Customer Service

 

SWAY BAR BUSHINGS!! I didn't realize you had not already done them. If you put the front up on stands and have your beautiful assistant turn the steering wheel lock-to-lock while you watch the sway bar you will see/hear/feel the clunk as the bar traverses. It is supposed to, but it will bang into the frame when the bushings wear.

 

Found my problem - It was sway bar related but not the bushings. The sway bar links bolt into a larger hole in the bar. It has to be torqued down tight or it will slide back and forth within the hole and cause a knocking/ clunk sound. It is hard to tighten because it requires an allen wrench and a 18 MM wrench. Knocking/ clunk sound is GONE!!!!!!!

 

I had a clunk in my 95 T bird with only 5,000 miles. The rear sway bar link came lose. I had to snug it down.

Stuff like this happens often no matter the brand.

My buddy had a Sonata that a weld broke on the bar and it hit the ground came up and did a lot of damage.

 

larger hole in the bar..?? does your sway bar have two holes at the ends where they connect to the links..??

 

I don't get the "Allen wrench" part either, the only Allen wrench I can think of on MY HHR is the headlight adjusters. But, yes the Squash nuts are difficult to get tightened down, you do need to hold the "flats" while tightening the nuts, I did have that problem at one time! May be that some replacement parts have an Allen arrangement rather than a "hex flat", just not either of the ones I've used.

 

I have an '07 LS that I bought 1 1/2 yrs ago with 60k and now 90k on it. I've replaced the sway bar end links with Moogs, sway bar bushings with aftermarket greasable ones, both strut assemblies to include top bushings, intermediate steering shaft, and I still get a very noticeable clunk when I go over any kind of ripples in the road or especially a speedbump. I've never had a car before that clunks like this, and I've owned a BMW, VW, Chevette, Oldsmobile, Nissan, Honda, and now this HHR. There has to be some kind of design flaw that enables something in the suspension to hit something else under the car. Search me what though. No one seems to have a real reason as to the cause of this. I really like this car overall, and have just decided that its a characteristic that isn't going to change and just comes with the car. Its kind of annoying, but it isn't a show stopper.

 

Did you by any chance use the Monroe Quick Struts? That may be part of your current problem. Some say that the springs are wrong for the HHR, look for a wear pattern between the top coils, they may be banging into each other. I have not had the problem, just read about it here.

 

The strut assemblies that got put on my car are the Monroe ones. I'll have to take a look and see if there is any wear at the top of the springs, although I don't think that is what is happening. I have some ripples in the pavement close to my house, and just going over them at 10mph produces a clunking sound in the front end.