Thunk/Popping Noise after Strut Replacement: CV?

Hi all. I’ve lurked on here for a few years to get my answers, but now I’ve got one I don’t know about.

I replaced the front struts (completely new full assemblies) on my 2011 a few weeks ago. During installation, the driver side half axle came out a little inboard at the transmission and had to be worked back in (per a great thread on these boards). Boot remained connected at both ends, no breaks/damage I could see. At about 80 miles of driving after the job, I started hearing an intermittent pop or thunk that seems to be coming from the front driver’s side. It’s not constant: might thunk once, might thunk a few times when going over bumps and turning (mostly left turns but will do on right sometimes). Steadily getting more frequent since. Replaced the sway bar bushings, new linkages: same noise. Took it in to a mechanic who said one or both of the coils on the new assemblies were hitting the struts. Took those off and replaced with a new pair of KYB struts (again, full assemblies, not playing with compressing those coils!). Rides great, but again, same noise. Was thinking one or both of the axles inboard at the transmission, but still not seeing any breaks in the boots. They definitely look old/worn at the inboard ends, but seem intact. Any way to know/check without just replacing? Anything else I should look at first? Seems kind of odd to me that one or both would just go right after the new struts. Was the drivers side one coming out during the job a red flag? Thanks in advance, folks.

 

Yeah, definitely not a clicking sound. Thanks, RMB.

 

I did. Same noise before and after.

 

Top mounts were same (far as I can tell) on both. I had a good discount on top of a sale and got the KYB completed set of two for a little over $300 total.

 

I'm resurrecting this zombie: I gave in and took it to a mechanic who swore up and down that it had to be a bad strut mount. This was the second new complete strut since the noise started, but, okay, could happen I guess. It was under warranty, so I shipped it back, got a refund, tracked down another KYB from a different retailer and slapped it on: same clunk over bumps and some turns.

This sound only started very shortly after replacing the struts for the first time at 150K miles. Have now replaced with three new struts since from three different retailers: one Unity, then two KYB, same noise. So, pretty confident it's not the strut or mount. This is the driver side only. I changed both at the same time, but the passenger side has never given me any issue. Then replaced the linkage on each side, new sway bar bushings...noise continued. I've been holding off on doing the alignment until I had this sorted, but should I go ahead and do it and see if that makes a difference? Driving, I'm not feeling any significant alignment issues. Any thoughts?

 

Any suggestions about who I might check with to have it rebuilt? Only things around me are chain mechanics and I have no idea if they do part rebuilds like a local, non-franchise mechanic. If I just buy a new one, what's a good quality brand?

Definitely going to do the trans fluid flush while I'm at it. Have the parts priced now. Thanks for that!

Visually, they look old, but fine. Though, I'm thinking about just replacing them anyway due to the mileage and opportunity while I've got everything apart already. What's a good, quality brand for replacement?

 

Hi. I gave up (again) and took it to another mechanic who figured it out and fixed it. It was the linkage on either the driver or passenger side. I thought I’d tightened them to spec, but apparently not. They tightened them real quick and that solved it. $45. I hope it’s that simple for you, too.