So folks, I've been going through everything to find a clunk, and every where I fix, I develop a new one LOL, it's starting to bug. I'll be jacking the car up tonight to look further and I have a hunch as to what it is this time.

It all started with a clunk only when pulling out of my garage, and an occasional click/clunk at full lock.

Found upper passenger motor mount was bad
- replaced.
Found lower motor mount was bad
- replaced.
Decided to upgrade my suspension to the Bilstein PSS-10 kit as I'm done pulling down the rear struts to adjust the damper for track.
- Replaced all sway bar end links front and rear.
Found both axles had torn CV boots (like all the way torn)
- Had the shop do the axles for warranty purposes.

So today, I drive it home, and there is a clunk on the rear driver side at low speed on bumpy roads, almost sounds like threads (makes me nervous on a brand new $2200 suspension setup). Interestingly, I asked them to check the rear driver side brake as I had an occasional squeak. (mind you, NO clunk on the way to the shop this morning from this area of the car).

For good measure, I'm going to uninstall the strut, inspect, and reinstall again. My hunch is the top nut may not be tightened down all the way as when assembling, there is a slightly tapered area the top mount will sit on, if thats the case, my body weight should be enough to reproduce the movement. I'll also double check the sway bar end links to make sure they are completely tight, but outside of these items, anyone else had this issue with the PSS-10 Bilstein setup? While embarrassed, I'm hoping it was my oversight that is the root cause.

More to come...

 

Sometimes the stupidest solution is the right one.

I had a bag in the trunk that had my coilover wrenches as well as my old tachs lol. Removed and sound is gone.. boy I feel stupid lol

 

Don't feel bad.
When I figured out a clunk was due to the top rear shock mounts (not pre loading the trailing arms during install/ tightening down the top shock bolts) = Solved the clunking noise.
Not long after; again, I kept hearing a soft clunking noise. It nearly drove me insane for weeks as I couldn't figure out what it was.
One day while at a do-it-yourself car wash, I was pressure washing the right rear inside wheel well and heard a familiar sound/soft clunk.
The inside bottom edge of the plastic wheel well liner was loose and knocking against the inside frame/body.There is no screw or clip in that area to hold it in place.
Secured it down with some hot melt glue. Never to be heard again.
That was about a year ago.

 

Indeed. At the dealership whenever a car came in with a noise complaint, my first step was to empty the vehicle of the owner's loose personal contents to determine whether the source of the noise was the vehicle or all the junk the owner drives around with.

Anyway, I'm glad it was a simple "fix"!