Front end annoying clunking noise

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mkc1962

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I checked all the mounts for the front differential All were ok. 2006 has small cv shafts/axles for the front wheel drive part, no actual mounts for the axle on the driver side.
 

DRS1

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I have had a similar thing since we owned ours from mile 1 back in 2003. It did not start until about 30k. It appears to be the exhaust system. Like the Crown Vic's of old that had a weight used for some kind of harmonic damper. When going over bumps it rattles. Also cat shields will bump and rattle if not kept tight and lubricated on the mounts. My .02


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mkc1962

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I have had a similar thing since we owned ours from mile 1 back in 2003. It did not start until about 30k. It appears to be the exhaust system. Like the Crown Vic's of old that had a weight used for some kind of harmonic damper. When going over bumps it rattles. Also cat shields will bump and rattle if not kept tight and lubricated on the mounts. My .02

Thanks for the input have checked all of that and all is quite tight and intact. This is no tinny rattling noise, when it happens it sounds like the entire front end (under or near my left foot) is about to fall out, very disturbing noise. Very heavy deep toned clunking sound.

Even my Alignment shop that Ive used for over 25 years heard it, and even he could not find anything loose/damaged or otherwise anywhere under the truck.

I am yet to check the idea of the stabilizer bar mount, or the CV shaft idea the alignment shop suggested as Ive been overly busy at work and have not even driven the thing in near a month. BUT both are on my list next time I get a chance.
 

MacMarkkus

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So figured out my clunking noise - ended up being front drive shafts. Took into Woodridge Ford in Calgary and they sorted it all out in one afternoon for $500 bux. Not pocket change by any means but i will save that on gas in a few months. Its down from 19.1 to 15.4 km/l now so I am happy. Till the next thing. Which appears to be a slight stuttering in the engine at low revs. Ah well...... :) Next forum topic methinks
 
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mkc1962

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Front CV shafts is on my suspect list. As they are about $50 exchange, and a few hours of work, its on my list to just replace when I get the chance. It is the only frent end item that is still old on mine.
 
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mkc1962

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I finally got the time to pull the front DS CV shaft. Upon removal it did appear to have some sort of rotational slack. This gave me high hopes that I would eventually solve this annoying clunking noise. I obtained a new one with Lifetime warranty from Advance Auto $52. (they price matched Rockauto).

BUT, still not the fix. Getting close to just forgetting it and living with it until something obvious shows itself. One of the most annoying problems to find I have ever had in all my days of wrenching.
 

BIG GREEN FORD

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Has anyone checked there hubs ??? Or for the 2wd expy have u checked to see if your brake disk it brings a bearing inside that wears out. Struts without bushings. Tie rood ends all 4. Idler arm, pitman arm,:think:
 
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mkc1962

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Well so far, all that has been spent was on things that were worn out and needing replacing anyway. And yes I have checked and or replaced (due to wear) all that has been mentioned. Though I have not done any checking on the torsion bars yet. In all the trucks I have owned over the years, I just have never seen one that had any issues with torsion bars.

I did not start down this path due to this odd clunking noise, it started with the air suspension failing and while doing that went ahead and brought the suspension back up to spec. The clunking was also there, BUT was not there when I bought the thing. I figured while fixing everything else, I would try and also solve the clunk, but so far no luck finding its source.
 
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