Is there something I am missing? (Front Suspension Clunking)

SMichaelG2 · Oct 3, 2017

I have a 2004 Expedition XLT 2WD 4.6L.

I replaced the following parts as the truck has 193,000 miles:

- Lower control arm assemblies
- Upper control arm assemblies
- Outer tie rods
- Inner tie rods
- Struts with springs
- Stabilizer bar bushings
- Stabilizer bar links

The hubs do not seem to have any play. The clunking is the worst on washboard like road imperfections. It sounds like the noise happens as the suspension goes both up and down. Am I missing something, or could one of the parts I replaced be bad? They were all ordered through Rock Auto, and no parts appeared to be damaged when I installed them. Anyway, just wondered if anyone had this happen, as I thought replacing all of that would cure the problem.

John Christopher · Oct 3, 2017

Check to make sure the struts are firmly installed. Loose struts could cause clunking. If they are tight, I would put a lever under the tire and add some pressure to check that the other parts are installed correctly. Good luck.

SMichaelG2 · Dec 25, 2018

I don’t like when solutions aren’t posted so here is what fixed my truck.

The replaced sway bar link on the driver side was defective. Until it wore down a bit more, I couldn’t figure it out. I replaced every single piece on the suspension, so I was super upset that it sounded so rough on bumpy roads. Turns out the $15 sway bar links from RockAuto weren’t all that great. The passenger side was fine but I replaced it as well. I am happy now though, the truck drives like new.

While I was replacing that, I also replaced the master cylinder, condenser, drier, expansion valves, all new o-rings on AC, struts again(squeaky and the ones I bought were cheap crap before), hubs, wheel speed sensors, positive terminal, battery, idle air control valve, fuel filter, and fuel pump. I also added a grille guard, which I really like. Hope my update can help someone in the future.

Trainmaster · Dec 25, 2018

The sway bar bushings (that mount to the frame) also wear and the bar can go clunk clunk inside them.

guspech750 · Dec 25, 2018

Maybe it’s related or not. But my 2002 F250 used to make loud clunking noises while driving over imperfect parts of the road. I replaced the ball joints and everything has been nice and quiet since.

Sent from my iPhone using Tapatalk

Retiredusps · Dec 25, 2018

Check the Production Date of the expy. There were 2 different styles one is cone shaped and the other is sort of square.I put the wrong ones on my wifes about a month ago never would of thought there was a different model. Also check the radiator mount/ cross member ours was rotted out and made clunking sounds. Not a hard repair only about $125.00 for parts.Took me about 3 days by myself.

jeremiahm · Dec 27, 2018

check the top nut on the struts (that holds the assembly together). I did all this work last summer and chased a stupid clunk for months. Finally discovered it was the top nuts. I had to pull them off (with car on ground) and put a thick washer to get the fully tight. Just the tiny bit of play they had translated to huge clunk noises.

Is there something I am missing? (Front Suspension Clunking)

SMichaelG2

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John Christopher

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SMichaelG2

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Trainmaster

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guspech750

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