Front end annoying clunking noise

[mkc1962]

I got this truck last year with 109k. Soon after I got it home I started hearing a clunking noise coming from the driver side front end, mainly when only on a bumpy road. I had similar on my old ford so suspected either a tie rod end or control arms. I did the following,

New upper control arm and ball Joints.( both lower joints were extremely sloppy) New Lower Ball joints. removed lower control arm for inspection during that but bushings were fine. New Tie rod ends as 1 was looser than I cared to see. Only item I saw left was the small stabilizer link But it did not appear to have much wear. I also recently did a Air to coilover conversion. Here I am after all that and Still when I go over a bumpy terrain I hear that annoying clunking noise. Ive ordered the stabilizer links just for the heck of it, but really have doubts that is the problem.

Any ideas on any joint I may have overlooked or someone that has experienced similar?

 

[Copper93]

Expys are know for snapping stabilizer bolts. I had to replace mine when I bought mine.

 

[mkc1962]

When you say stabilizer bolts....are you referring to the bolts that are in the hold down arm that holds the stabilizer rod to the chassis?

If its what I am thinking it is, that would be just about under my left foot when driving, and that is about where it seems the sound is coming from.

 

[mkc1962]

Crawled uner truck last night. If the stabilizier bolts are those I am refering to in my reply above. Then no they look ok. just guessing approx 5/16" x 3" long, mounted from frame downward with nuts on the stabilizer bar clamp. All appeared to be snug and not broken.

 

[Copper93]

They go from the lower control arm to the ends of the bar. They have a plastic or metal sleeve on them and are about 6 inches long. Mine rotted and broke inside the sleeve and I couldn't tell until I pushed up on the bar and pulled them apart.

 

[Copper93]

Ford Explorer Front Sway Bar Link Replacement - YouTube

 

[mkc1962]

Yeah Stabilizer links (sway bar links) is what I have ordered as mine has a small amount of play in it . But, you mentioned stabilizer BOLTS. BOLTS is what I was asking the location of. Still waiting on the links to arrive, and maybe that is the noise I am hearing, but they sure dont appear worn enough to making the loud noise I am hearing. They are surely not broken.

 

[mkc1962]

Stabilizer links arrived yesterday. Installed this morning. Took for test ride and appears may have fixed the noise. The only thing that bothers me is the links/joints I removed sure did not seem very loose at all, though they were a bit looser than the new ones. Thanks for the feedback Copper.

 

[splintrcel]

My truck snapped both links and it wasnt too bad to replace. The hardest part was getting the old ones out. They had to come out in pieces

 

[mkc1962]

grrrr....spoke too soon. We went out of town this weekend and after about 30 mins down the road, there we go again. Stabilizer links was definately Not the cure. Still very obvious that is it coming from the driver front side, but I have replaced or inspected every single joint that moves and ever bolt or nut on that side of the front end. Including the door hinges, chassis mounts and running board mounts....not a clue here.

 

[Potatoes]

I have the same problem in my Expedition. I haven't been able to find the cause of the problem...it's awfully annoying.

 

[BigG~]

grrrr....spoke too soon. We went out of town this weekend and after about 30 mins down the road, there we go again. Stabilizer links was definately Not the cure. Still very obvious that is it coming from the driver front side, but I have replaced or inspected every single joint that moves and ever bolt or nut on that side of the front end. Including the door hinges, chassis mounts and running board mounts....not a clue here.

I hadda' replace mine a few times, till I found a set from ENERGY SUSPENSION and never hadda' problem since.!! Ck them out...?
I can get you a part number if it would help, there built a hell of a lot tuffer than MOOGS or whatever pep boys is selling these days.. G~

 

[FordandPolaris]

grrrr....spoke too soon. We went out of town this weekend and after about 30 mins down the road, there we go again. Stabilizer links was definately Not the cure. Still very obvious that is it coming from the driver front side, but I have replaced or inspected every single joint that moves and ever bolt or nut on that side of the front end. Including the door hinges, chassis mounts and running board mounts....not a clue here.

My folks have an 04 with the same issue. I completely rebuilt the front suspension last summer in that truck and it still clunks. I know your frustration, but unfortunately I have no answers...

 

[mindgame]

Transmission cross member bolts loose? (2 bolts under driver and passenger side). Replace with Grade8 13x1/2 bolts..

 

[Copper93]

Are you positive it is suspension related? Could it be a exhaust hanger or heat shield that is loose? Sounds like you replaced everything else.

 

[mkc1962]

Ive checked and or attempted to tighten every posssible bolt found from the transmission forward. Not to include all of the new suspension stuff. Very obvious coming from front driver side, just cannot pin point it. About to say the heck with it, and just let it go till something for sure shows a cause. Nothing of any safety related item is not new, so not worried about any sort of dangerous failure. Just damn annoying.

deep sounding clunk, very similar to what a bad ball joint, control arm or similar might make if it were going. Definately not a lighter tinny type of sound like exhaust or metal shielding might make.

 

[BigG~]

Frt end clunk..?

P/U a set of Energy Suspension #9.8119 End Links and tighten them down good n' tight... If they have play in them you will still getta clunk, especialy hard turning.................. I replaced mine with these after losing a couple pair and my truck now handles like my Vette and haven't lost one in the past 2 years... And I gotta' lotta stress on mine as I got a lift a bigger tires on mine. There thicker and the bushings are by far better than anything else you can get..!! Try it, ya' won't regret it.. G~

 

[mindgame]

Ive checked and or attempted to tighten every posssible bolt found from the transmission forward. Not to include all of the new suspension stuff. Very obvious coming from front driver side, just cannot pin point it. About to say the heck with it, and just let it go till something for sure shows a cause. Nothing of any safety related item is not new, so not worried about any sort of dangerous failure. Just damn annoying.

deep sounding clunk, very similar to what a bad ball joint, control arm or similar might make if it were going. Definately not a lighter tinny type of sound like exhaust or metal shielding might make.

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[MacMarkkus]

Newbie to forum here - dont know if this is quite same problem, but do you notice it more so when slowing down?? I have a knocking style noise when i am coming to a halt, but again its the front drivers side wheel area. Probably going to bite the bullet and leave into ford as i have a little guy who i dont want to be in a risky car. Will post outcome here when she comes back all fiksed

 

[mkc1962]

Most commonly noticed when going over uneven terrain, regardless of dirt,gravel, or pavement. Have not noticed during the braking or slowing process UNLESS it is also on the uneven terrain.

So obvious sometimes, it makes one wonder if some part of the front end is about to fall out or off.