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Thanks gents. After I threw sway bar links at it, my next thought was the subframe was loose. I had dropped it to get the front diff in a few years ago, but I checked and all the bolts were torqued correctly. I also checked the stiffener plate because that can cause a nasty and scary clunk as the subframe flexes under braking, if it isn't tight. Ask me how I know! All good there.
I feel it has to be the right ball joint that I can't get out (that the tension strut attaches too). It was really floppy and actually had at tiny bit of vertical play in it. I am imagining this play causing the tension strut to bang against the knuckle over bigger bumps.
the clunk is much better, so I suspect my bushings were failing too. Maybe it was all related. At any rate, its drivable and feels good with the new bushings, and I found what looks to be a decent right front carrier/knuckle on ebay for dirt cheap, and I ordered a new bearing kit from FCP. Unfortunately after consulting Bentley, it looks like I'll need a new hub too as it says they are trashed once you pull them out of the bearing. That will be the most expensive part at $140 on FCP. After I clean it up and shoot it with some rustoleum, I'll take the whole thing down to my local suspension shop and have them press everything out, and the new bearing and hub in. The left side is only a bit loose, so I can take my time on that one. Ebay has those knuckles for $60!
At this point, I think I can swap a new carrier/knuckle in faster than I could get the stripped ball joint out, and I get a new bearing for little effort. I broke down and bought the tool to pullthe axle into the hub, which makes this stuff so much faster and easier. I'll also be able to get some new grease into the right CV joint, and get a new clamp on it. Its been throwing grease for months in slow motion as I clearly didn't get the clamp tight enough when I did that axle.
Unfortunately I'll need yet another alignment though.
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Current
Original owner 2002 E53 X5 4.4i to 4.6i swap
2026 G80 M3 6 spd
2025 G06 X5 50e
Former
1972 Audi Fox
1986 Saab 900S
1996 BMW Z3
1998 BMW E36 M3 Sedan
2004 BMW E46 M3
2006 Audi A3 Quatro
1993 Mopar 318 Jeep Grand Cherokee
2015 V6 Jeep Grand Cherokee
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