Front end annoying clunking noise

[BIG GREEN FORD]

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.

 

[megamike308]

Have you checked your shocks?

 

[mkc1962]

All new due to an air ride to coilover conversion. But yes checked several times since.

As for torsion bars, I dont think a 2006 has them does it? FSM sure doesnt list them.

...and yes, very annoying.

 

[bowman1268]

mkc I feel ya

Mine is doing the same thing only things left I havn't replaced are torsion bars.I hate the fact that I will be driving around and it is riding perfect and quite.I get my hopes up that it is fixed then bam I hit a bump or turn just right and clunk then may not do it again or may not and no matter how many bumps I hit on purpose I can never make it do it when I want it to.I have ocd so I am actually loosing sleep over this stupidness.

 

[ogre20012001]

One thing that hasn't been mentioned is wheel bearings.
I had a set go bad but never got loose. They just made noise.


Sent from my iPhone using Tapatalk

 

[mkc1962]

Wheel bearings on a 2006 reside within a sealed hub assembly. Have to look back and see if I posted that or not, but yes replaced the hub assembly on the side making the noise. Still to this day does it, still cant find the cause.

 

[akosundalo98]

I have the same issue in a 2000 when I take out the front drive shaft it goes away. I have tried 2 new driveshafts to no avail put driveshaft back in noise comes back so for now I have a 2wd. I was think front rear but no clue

 

[jeremiahm]

I have a clunk in the same general area when going over bumpy terrain, potholes, etc. Haven't had a chance to check all the nuts and bolts but when putting a level kit in the front I noticed that my steering rod from the rack unit to the driver side TRE has movement at the rack, not the TRE. Pulled the TRE and I can push/pull the rod in and out just a tiny bit, and it makes a small clunk that I think translates to a big clunk when driving. I did the same on the passanger side and it is tight, no movement. Don't know if this can be adjusted, but worth a shot.

 

[mkc1962]

Its been a while since I've worried about this much. However any new input is greatly appreciated. I do recall checking all of that, but next time I have it up on the lift will sure check that part again.

 

[2004XLT]

I had a noise I couldn't pin down. This was on a fully rebuilt front end including rack and steering shaft. I greased the slip joint in the front driveshaft and greased the steering shaft slip joint and the connections to the steering column and to the rack shaft. Also lifted the small plastic cover the rack shaft comes out of and packed that with grease. I used wheel bearing grease for everything. For the first time the exp is 100% noise free. Also have less vibration coming through the steering wheel on rough roads. Chevy truck owners have been greasing the slip joint on the steering shaft for years, but for some reason no one has suggested it on any Ford forum that I've seen.

 

[Jfpound]

Anybody else try this? I have the same clunking.

 

[2004XLT]

Another thought, worn out front axle bearings can make noise (knock noise). I just did mine and they were easy, I replaced the seals while I had it apart because they were leaking. I think I remember reading that you replaced sway bar links, but my $30/ea Raybestos pro grade greasable links were done at 2,000 miles. Can't be checked accurately until you pull them from the car. Something to think about.

 

[bowman1268]

Sorry I thought I posted a update.Mine ended up being a bolt that was not torqued down properly when I had my upper control arms replaced.It took a few months for the bolt to work loose a bit and cause the intermittent noise.

 

[mkc1962]

Yes my bearings were also done, stabilizer links I used Moog and yes have pulled them more than once for inspection just to be sure. Every bolt on the entire front end has been double checked for proper torque several times. Still doing it to date. Have for the most part given up chasing this ghost.

 

[2004XLT]

I would be interested to hear the noise maybe on a video. The previous owner of mine didn't do a thing so I've had to go through everything on this car plus some and figured out a lot that's specific to expeditions.

 

[Norexp]

I have had a clunking sound from front end for a while. Changed upper and lower control arms, outer tie rods, stabilizer bar bushings, stabilizer links, hubs and alignment two times. Inner tie rods are fine.

Last inspection said I have play in steering rack, and for sure there is where the sound is coming from.

I removed steering shaft, cleaned and lubricated it, and when I wiggle the shaft while disconnected at top, I can hear the sound.

Rack and pinion can be adjusted, but space is tight. i will try to tighten it one day, to get rid of play and sound.

Might be the same problem you have.

 

[2004XLT]

I have had a clunking sound from front end for a while. Changed upper and lower control arms, outer tie rods, stabilizer bar bushings, stabilizer links, hubs and alignment two times. Inner tie rods are fine.

Last inspection said I have play in steering rack, and for sure there is where the sound is coming from.

I removed steering shaft, cleaned and lubricated it, and when I wiggle the shaft while disconnected at top, I can hear the sound.

Rack and pinion can be adjusted, but space is tight. i will try to tighten it one day, to get rid of play and sound.

Might be the same problem you have.

How do you adjust the steering rack on a second gen expedition?

 

[Norexp]

There is a locking nut in front of the pinion, right in front of cross member. Loosen lock nut, and CAREFULLY tighten nut inside. Maybe just 1/8 turn. Too much and steering will be stiff, and might loose self centering.

Space is tight behind cross member, so might need to loosen outer tie rods and steering rack bolts, to gain access. I havent done it yet, but I will do when I have spare time.

 

[mkc1962]

Ive tried to check the steering rack for any slack, but have not disconnected it to try that way. May give it a try next time I have it up on the lift.

 

[2004XLT]

Interesting about the steering rack adjustment. There's something like 150 pages about the racks knocking on an f150 forum and the concensus is that they could not be adjusted. I took a look under mine and I see what you mean though. probably don't even need to remove the wheels or tie rods to access the adjustment, just remove bolts holding the rack to frame and slide it back just enough.

At this point why not buy chassis ears and get this problem solved?