Help diagnosing clunking suspension noise

[TheDoug]

I have a weird clunking noise coming from front suspension when I go off pavement or on rough road. It seems to be worse when cold.

I have hellwig sway bars and I have double checked end links. I also have skid plates and I have doubled checked clearances on those as well. Nothing is rubbing or banging.

I looked at front strut and nothing seems to be leaking. I have CCD suspension. Could a strut be bad without visible leaks? Where else should I look?

Thanks in advance everyone.

 

[apex96]

Checked upper and lower ball joints? Typically ball joints will pop when failing but it’s worth a look.

Are you certain the end links aren’t bad, they can still feel good but are wearing internally and making grooves in the ball end.

The bushings that the sway bar runs through may be going bad and it’s shifting against the frame causing the clunk.

Check tie rod ends as well for excessive play.

Also want to add that I’ve had end links fail in the rear and the sound traveled through the chassis and sounded like it was occurring in the front end. Don’t overlook your rear end mounting points as well.

 

[TheDoug]

I have checked the rear as well... All sway bar end links have less than 20k on them and look good.

I have not checked tie rods or ball joints though, thanks for the tip.

 

[Deadman]

Hellwigs front sway bar bushings are junk. Mine go bad every 20,000 miles and they clunk on every seam in the road now.

 

[TheDoug]

Hellwigs front sway bar bushings are junk. Mine go bad every 20,000 miles and they clunk on every seam in the road now.

I should have mentioned I replaced mine shortly after I bought them with the ones recommended on this forum. (The hellwig ones were crap)

 

[LouG921]

I recently got a 2nd Gen, 2006 Expedition with the clunking noise. The front suspension parts looked great.
One mechanic said steering rack.
One alignment shop that charged for diagnosis said steering rack, + bushings and big bucks.
Another alignment shop that charged for diagnosis could not say, but said start with sway bar links.
On the forum, there was a mention in a couple posts about sway bar links.
Sway bar links cured the clunks !
Suggest you change sway bar links - cheapest part of the suspension.
The question I have is "Don't these professional technicians know anything?"

 

[zak99b5]

Any resolution to this? I’m hearing a rattle that seems to be caused by having the front wheels turned and going over bumps, such as entering a driveway. Everything underneath looks ok, including the hellwig rsb I installed a few months ago, amd rocking the truck with it parked makes no sound.

 

[jar0023]

Make sure you check the sway bar links without weight on them. Partial lift of the front should be enough. My 18 eats end links like they are candy. I’ve yet to find an AM set in links that will last 20k miles. Switch ing back to OE this weekend.

 

[apex96]

It’s funny that I listed off a lot of wear items that could make a clunk… Now it’s my turn to track down a mystery clunk. I’ve replaced and checked every component on the front end minus the upper and lower control arms, ball joints, abd tie rod ends. I did check the ball joints and they’re all tight still. Had the transmission out for a torque converter replacement and a clunk was present afterwards. Having a dealership go over it, coming up to try and pin it down… could be anything in the front driveline and steering gear at this point.

 

[LegalBrief]

It’s funny that I listed off a lot of wear items that could make a clunk… Now it’s my turn to track down a mystery clunk. I’ve replaced and checked every component on the front end minus the upper and lower control arms, ball joints, abd tie rod ends. I did check the ball joints and they’re all tight still. Had the transmission out for a torque converter replacement and a clunk was present afterwards. Having a dealership go over it, coming up to try and pin it down… could be anything in the front driveline and steering gear at this point.

Upper Tie Rod or Upper Control Arm. Very hard to diagnose. Raise truck pull on tire up to down, if you hear the clunk. Failure may only be on one side but given your trucks age then change both.

 

[apex96]

Upper Tie Rod or Upper Control Arm. Very hard to diagnose. Raise truck pull on tire up to down, if you hear the clunk. Failure may only be on one side but given your trucks age then change both.

Had the truck lifted by the lower control arm to take the stress off the ball joints. Couldn’t find any movement in the upper or lower ball joints for both sides. Used a long pry bar to stress them. Didn’t check tie rods yet.

 

[sagebrush07]

Any update on this clunk?

 

[Going_Going_Gone]

When mine developed a similar "clunk" sound, we re-greased the sway bar bushings with silicone grease and the "clunk" went away. Recently drove the Monument Valley scenic loop which has some serious washboard and rough rock sections, without a sound.

 

[bryz_expy]

I’ve experienced this clunk in the front drivers side and it’s more often noticed when cold and slow speed first drive of the day. Dealer can’t find it either.
I read a while back that someone determined it to be a body panel or channel seam contact with the frame, but I cannot recall the details or the thread where I read it. It sounds like a control arm from previous vehicles, a hallow sounding clunk/ pop.

 

[apex96]

Any update on this clunk?

Dealer was able to replicate the clunk, it's coming from the lower spring perch on the drivers side front strut/shock assembly. I have aftermarket bilstien 5100s installed and reused the lower perch from the OEM strut/shock assembly. Dealer is unwilling to go further since it's aftermarket. Once I get it home, this coming weekend I'll investigate to see if the perch truly failed/is failing or if the C-clip that allows height adjustment has dropped down a notch. I'm really hoping it's just a C-clip issue and that it hasn't damaged the grooves... Ford will not sell parts and pieces to the shock/strut assembly.

 

[Expedition_Feste]

Dealer was able to replicate the clunk, it's coming from the lower spring perch on the drivers side front strut/shock assembly. I have aftermarket bilstien 5100s installed and reused the lower perch from the OEM strut/shock assembly. Dealer is unwilling to go further since it's aftermarket. Once I get it home, this coming weekend I'll investigate to see if the perch truly failed/is failing or if the C-clip that allows height adjustment has dropped down a notch. I'm really hoping it's just a C-clip issue and that it hasn't damaged the grooves... Ford will not sell parts and pieces to the shock/strut assembly.

any update on this as I'm curious if they really found the culprit or just guessing it was that based on them seeing the aftermarket shocks and saying that b/c it was easier to diagnose since they weren't going to dive into remedy. Seems unusual as its pretty much the same design as factory. Im running the bilsteins as well.

 

[Bmac1955]

Dealer was able to replicate the clunk, it's coming from the lower spring perch on the drivers side front strut/shock assembly. I have aftermarket bilstien 5100s installed and reused the lower perch from the OEM strut/shock assembly. Dealer is unwilling to go further since it's aftermarket. Once I get it home, this coming weekend I'll investigate to see if the perch truly failed/is failing or if the C-clip that allows height adjustment has dropped down a notch. I'm really hoping it's just a C-clip issue and that it hasn't damaged the grooves... Ford will not sell parts and pieces to the shock/strut assembly.

I had Bilsteins put on my front end in 2023. I had them installed with 39k (2019) due to right front leaking. I have experienced that same clunk on the left front when first driving off with a left turn. Seems only happen on first drive of the day. I had rears replaced at the same time along with Hellwig sway bars. Since I have put 5k on it and perplexed with the noise. Thought possible swaybar links and now reading this post I am confused. Probably will replace end links on the front end and go from their.

 

[5280tunage]

I had Bilsteins put on my front end in 2023. I had them installed with 39k (2019) due to right front leaking. I have experienced that same clunk on the left front when first driving off with a left turn. Seems only happen on first drive of the day. I had rears replaced at the same time along with Hellwig sway bars. Since I have put 5k on it and perplexed with the noise. Thought possible swaybar links and now reading this post I am confused. Probably will replace end links on the front end and go from their.

The end links have been a pain in the rear for me, I have several posts on here about what i ended up doing. long story short, I do not believe the factory end links can handle the amount of torque the hellwig bars can create, my factory links started popping in about 2k miles. And yes, the bar was installed correctly, even had it reviewed by Hellwig.

I tried numerous aftermarket end links, but part of the issue is the design. Anyone that does a lot of off roading knows which socket types and materials hold up well to increased torque, so I ended up going with a set of energy suspension "universal" links. The reason I did those is because bushings on all contact surfaces. It has helped, but it took me a while to dial in the right length of spacer and bolt assembly. It's frustrating, the bolt has to be long enough to allow for enough play to get both sides together, before cranking it down. I wish there as a good aftermarket heavy duty end link for these. Companies like JKS make some awesome end links, just not for this thing.

 

[Bmac1955]

Thanks for that info. Yet, I don't do off road driving so I do believe that is sound advice to look into.

 

[Benztech]

Get some chassis ears. I have the Steelman brand and they work great, but as usual Amazon has cheap options. Use tape or Velcro straps to secure the wires.