Originally Posted by DK Pony
First thing I would be suspect of is if you reused the stock Upper Strut Mounts. They are notorious for clunking/popping after they have been removed and reinstalled.
Just a new set of factory ones will help but the GT 500 mounts are the preferred replacement.
I realize you said you checked the bearing on the USM's but it usually is the issue.
Check the front end links. They are tough to get back to torque specs because of the location. 85 lb/ft. And they are pretty wimpy.
Other than that just check the torque settings on everything.
That's all I've got.
Yep on both things. Upper strut mounts should be replaced when you replace the struts even if they 'look' ok.
To get the bottom bolts of the stabilizer bar links torqued down properly, I ended up removing the stabilizer bar with the end links attached, torqueing the links onto the bar while the bar was out, then putting the bar back in with the links already attached. There are two u-brackets (two bolts per bracket) that hold the bar to the frame. These are Torqued to 52 ft/lbs.
The top part of the links (to the strut) are easy to access with a TQ wrench.
Also check your stabilizer bar bushings while you have the bar out. There should be no cracks. In fact I would probably just replace them since you will have the bar out. The bushings can compress and cause play in the stabilizer bar.
Almost forgot, how low are you? You may need a bumpsteer kit. Even if you have cast/camber plates.