Rattling noise right turn under load, new axle

[rdeis]

Hello all, looking for some diagnostic help on a strange noise in my 1994 AWD.

It sounds like a CV rattle to me, coming from under the front of the car somewhere between the radio and the glove compartment., but lower. The noise happens with the car warmed up, turning right, under load. But I replaced the passenger side axle and it didn't go away. I'm pretty sure its not the drivers axle because the noise is coming from the left-center side of the car.

I think I heard it just a little at high RPM going straight up a hill the other day, too, but that's much less distinct, and in any case only when pushing it much harder that I usually do.. (Maybe because the exhaust note is louder and its hard to hear?) During the right turn, the noise comes on with a moderate load, and it goes away when I come off the gas.

The rattle is speed-dependent, not RPM dependent.

I haven't heard it turning left yet.

The car has over 180k miles and a newly-built 2.4 motor installed, original 5-speed tranny.

What's my issue?

 

[pauleyman]

Worn front diff bearings? Worn passenger wheel bearing? Any number of steering components contributing.

 

[rdeis]

When the wheel bearing went on my son's FWD, it made more of a thrum-thrum-thrum sound. This is a loud clattering? Unless play in the bearing annoys the CV joint, I suppose... Diff bearings would be unpleasant..

The car is using Eibach springs over KYB AGX struts (set full soft) and poly bushings, so it's a little lower and stiffer than stock..

Any ideas on how to track it down? I thought I might block up the car and see if I can get it to happen with all 4 wheels turning in the air.. It's really hard to pinpoint the source of the sound when you're driving or riding in it?

 

[pauleyman]

Are you sure it's passenger side. Did it do it any louder or softer before the axle change?

 

[rdeis]

> Are you sure it's passenger side.

Not as sure as I'd like to be. When driving it seems to be coming from near the passenger footwell. If it was a FWD with the long axle shaft I'd suspect the inside joint there, but it and AWD with the intermediate shaft so the inside joint is over on the other side.

> Did it do it any louder or softer before the axle change?

I don't think so, but my wife sits on that side of the car and she thinks it got quieter.

 

[rdeis]

Looong-overdue resolution: Weak/worn OEM motor mounts!

The engine was actually moving so much that the axel was binding up! We put the car on a lift and ran it through the gears and discovered excessive motor movement. Shifted to urethane inserts and all is well.