Help Diagnosing Front Clunk

[humbucker87]

At my DIY wits end and would love help diagnosing this noise before I take it to a shop.

Video of issue.
YouTube

The problem: over large bumps (think neighborhood 25 mph speed bumps) going fast 30mph I get this clunk. I don't get it going slower. I don't get it turning or braking. Only under severe and quick articulation of the suspension.

What I've tried:

1. removed front sway bar completely
2. new aftermarket Uca torqued to spec
3. new aftermarket lca torqued to spec
4. new inner and outer tie rod ends
5. new aftermarket axles
6. shocks are 5100s with about 20k miles and stock springs

Thanks in advance!

 

[Seasparrow]

I do not have these shocks but the internet has a few 5100's noise threads, If they are adjustable, can you re adjust them to a lower setting and drive again?

Some threads had this to say;

""I installed the 5100 shocks and had about 20,000km of trouble free driving. Last week a clunk started in the right front shock. Usually that means the washer wasn’t installed correctly. I’m 95% sure I did it right (20k of driving seems to prove that) but something is obviously wrong.
I tried tightening again and that helped but didn’t cure it."" Bilstein 5100 clunk after 20,000km | DODGE RAM FORUM

""Did you make sure to install the washer onto the shock piston rod before putting the upper isolator cap on, and then the locknut? From some owners who've done the install with pics, that is the one big mistake done when installing. What happens is the piston rod diameter is so close in diameter to the piston rod hole in the truck frame bracket that in a very short time with heavy front suspension dive, the rod will go through the truck frame bracket piston rod hole causing improper coilover operation. In turn causing damage to your new Bilstein piston rod. The OE piston rod has a built in tapered end that butts up against the frame bucket, then the isolator cap, then a washer and locknut. This is where the two shocks get confused during install.""

""Just had my fronts installed last night, no noise at all....I've read some people having a clunk after and they found the one bolt top center of shock the nut wasn't tightened down all the way...I also have mine set at top setting, I had my local 4 wheel shop install though..""

 

[humbucker87]

Wow thank you. I hadnt seen that but from reading i certainly think I am either missing the first washer all together or didn't install it correctly. I will check. Thanks again.

 

[humbucker87]

Watched a video of a 5100 install for a 5th gen and noticed a washer that I don't think mine have (or I didn't install).

Curious if others know if this washer should be there for 4th gen 5100's. I can't find any good picture or anything definitive for just the 4th gens. This is for the front shocks btw:

 

[royal T4R]

Curious if others know if this washer should be there for 4th gen 5100's.

I did not have that thick spacer with my 5100

 

[humbucker87]

Thanks for the quick reply. That's good to know.