I replaced the struts about 2 years ago with Monroe quick struts, after whatever was in there (OEM, or replacements) completely disintegrated in the strut mount area. Since they were about 6 months old, it started making a metallic scraping sound when going over bumps on the passenger side, it sounds like it's up near the windshield but definitely suspension related. I replaced the sway bar bushings, the links are good and tight. All bolts are tight. I have even pulled the strut out, and made sure the mount was intact and the strut nut was tight. I've been on youtube and found some people demonstrating noises when going over bumps, and they all sound more like a thump, which is associated with the sway bar bushings... but this isn't a thump. It sounds like two pieces of metal scraping together end to end. The strut tower looks ok, it's not rusted or anything. This noise is driving me mad... any ideas what else I could look for? I'm almost considering replacing the strut to see if that helps.

 

I have the exact same issue. I notice it when going over speed bumps and more noticeable when the van is cold. I have also replaced the shocks/struts, sway bar and wheel hub assemblies. I'm thinking it's got to do with the control arm.

Help to diagnose is needed.

 

I don't think it's a control arm in my case. The sound just sounds like it's coming from the very top of the strut. I can't replicate it by rocking the van, seems like it's more when i hit a dip in the road or a pot hole and the strut extends rapidly. I do notice it a little more in cold weather also.

 

Chrysler has issued a technical service bulletin with a fix for this issue in your van. The noise is originating in the rubber strut bumper in the strut assembly. The cure is to lubricate this area with a special lubricant. Even if the struts are replaed with new ones, this noise will occur if the new components were not properly lubricated during assembly.
I have provided a copy of the TSB below, so that you can point it out to the dealer service manager or service technician when you take it back to get them to fix the problem correctly (they will ahe a copy in their files, and should take care of the repair at no cost to you since they should have done the repair correctly the first time).
I hope this is helpful;
_________________
NUMBER: 02-004-05
GROUP: Chassis
DATE: May 27, 2005
SUBJECT:
Creaking/Squawking Sound From Front Strut Area

OVERVIEW:
This bulletin involves applying lubricant to the jounce bumper of both front struts.

MODELS:
2004 - 2005 (CS) Pacifica 2001 - 2005 (RS/RG) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION:
A creaking, squawking, squeaking, grinding, groaning sound from the front strut area while turning in either direction during low speed parking lot maneuvers.
DIAGNOSIS:
1.Raise the vehicle on a suitable hoist so that the front wheels hang free.
2.Locate the front strut dust boot and rotate the dust boot fore and aft or move side to side.
3.If the sound is present, perform the Repair Procedure.SPECIAL TOOLS/EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
1.Using the detailed service information available in TechCONNECT, remove and disassemble the left strut assembly.2.Apply a liberal amount of Nye Grease, p/n 05019061AA, to areas of the jounce bumper as illustrated (Fig. 1).
NOTE :In the figure below the small jounce bumper is used in CS and Short Wheel Base (SWB) RS/RG vehicles. The larger jounce bumper is used in Long Wheel Base (LWB) RS/RG vehicles.
3.Using the detailed service information available in TechCONNECT, assemble and install the left strut assembly in the vehicle.
4.Repeat Step #1 through Step #3 on the right side of the vehicle.
5.Verify front end alignment.
POLICY:
Reimbursable within the provisions of the warranty