2003 Exp Steering knock over bumps

[sdoherty]

Hello All,
I have no problems with the operation of the steering but I do hear a clunk when I hit bumps. I climbed under the truck and had an 'assistant' turn the wheel - I heard the clunk coming from the steering rack - kind of right in the middle of the rack.

I of course did a search and came up empty - so questions are;
1. Anybody else have this - I am leaning towards replacing the steering rack
B. Should I just drive it or is it doomed to fail with a screech and a bang

FYI I installed new struts all around and new upper control arms but the clunk was there before this work - also a small lift kit..

Thanks everyone!

 

[sdoherty]

It is actually coming from inside the steering gear connection to the rod

Here is where he noise is coming from - does the rubber cover come off the steering gear rack to provide some adjustment?

 

[captain chaos]

Check for play in the inner tie rods, which are hiding under the boot you have pictured. Any play in them will manifest itself as a clunk over bumps.
The boot you have pictured does indeed come off. It's held on by a crimped band that will have to be cut off. Replace it after removal though as you need it to seal out dirt/water. A hose clamp works fine. There is no adjustment in there per-se. The inner tie rods live in there though and I suspect you have one (or both) that are worn.

It is highly unlikely you have a problem with the rack itself.

 

[Hamfisted]

Yes, if you haven't replaced the inner tie rods and the lower ball joints yet I'd definitely look at those as culprits.


-Mike

 

[sdoherty]

steering clunk

Thanks Ham and Chaos..

I was rally trying to show in the picture the round cover on the bottom of the steering shaft with 4 slots. I am not sure if that is a pre-load or something I can adjust. I do not think it is the inner tie-rod or the steering rod connected to the steering wheel. It sounds like it is coming from the rack somewhere. Again no play in the steering both off the ground or driving.

Is everyone elses rack completely quiet?

Thank you

 

[Hamfisted]

My Expy's steering rack is quiet. 160k miles and only thing I've ever done to the steering is replace the inner tie rods and ball joints. I would take it to an alignment shop and let them at least look at it for you.


-Mike

 

[sdoherty]

Hello All,

Still have the noise so I took the big step of removing my steering rack - big job! SO anyway with the rack out I turned the shaft on the rack with a vice-grips and it seems smooth.

I was wondering it the noise could be from the shaft hitting/rubbing on the body - maybe by the engine mount support.

Can anyone check to see if possibly the shaft is near a point where it may bump. Since my rack is out I have no idea where the shaft actually rests.

thank you!

 

[2004XLT]

Have the same problem at 125k. This was an issue on many f150s. My front end is completely tight but it sounds like my ball joints are bad on both sides...recently it's become louder and it's obvious that it's coming from the rack. There is no adjustment. I think the noise isn't caused by rotation of the shaft but I bet if you grabbed it with vice grips and ****** it side to side you could get the noise. I checked the bolts that mount the rack to the frame and they were tight, at this point I'm just gonna drive it until it gets worse. I just went out and looked at mine and I don't see any way it would be hitting anything, I'm convinced the noise is internal like a bushing or something.

 

[2004XLT]

Did you end up replacing the rack? I'll be doing that soon if I can't fix it. I find it unbelieveable the steering rack on a half ton ford is shot at 125k.

 

[Lostneye]

The racks themselves don't fail as often as inner tie rods. The rack bushings can wear out as well

 

[2004XLT]

The only way I've known to check inner tie rods for wear is to push and pull on them and look for any play, mine seem to be tight. If I have someone sit in the drivers seat with the car off and quickly turn the wheel back and forth I can tell the noise is coming from right behind that black cover with the 4 notches in it. It's a metallic banging type noise. Are the bushings you're talking about replaceable?

 

[bubbadabulldawg]

You haven't checked the most obvious part, the noise is coming from the sway bar end links. I've replaced them with lifetime replacement units from Napa only to have them fail again a few months later so I went back with OEM Ford units.

 

[sdoherty]

got new rack..

Got my new rack from partsgeek and installled last night.. Have to finish job and test drive - still left to do is to put on tie rod ends..

This job was not too bad just be sure to make some room to operate -
-move radiator hose
-remove all intake plastic like air cleaner housing
-remove PS reservoir
-remove rubber piece under oil filter
-and of course 1 can of PB should be emptied on all nuts/bolts

Hopefully the test drive goes well..

 

[2004XLT]

I just did the replacement today, I used an AC Delco rack from rockauto. It's even noisier than the old rack. I'm interested to see how yours turns out, I've read on f150 forums that with these reman racks you need to go through 3 or 4 of them before you actually get one that's tight. I can't figure out a way to test the rack before it's installed, though.