Ford Brakes/Suspension :: Clunking And Rattling In Front End


Dec 18, 2012

I have had a clunk in the front end that started out as a light clunk that was sometimes noticeable. It has now turned into a clunk that can be heard very often. It sounds like a hollow clunk. I'll try to explain it so it makes sense...If I'm going over a bump or speed bump or something like that it doesn't really do it noticeably. If I'm driving a get to a place where the road is uneven or there is a hole or pothole and the front end seems to "fall into the hole", then the sound is very audible, and I can feel it slightly in the steering wheel and under my feet in the drivers floorboard. So, I've had the front end checked out 4 times and between what they said to do and what I've read on here...here is what I've done so far......

Changed end links with moog end links
Changed sway bar bushings with moog bushings
Undid the bushing mounts from the front frame and wired the sway bar up to keep from flopping around. No change in sounds
Didn't get rid of the clunk....

Had front end shop check out truck... They said ball joints were ok, no play in them. They did say that they could feel some "clicking in the pitman arm pivot" when turning the wheel. Like something was loose in box.

I've changed shocks and bearings.

I can grab a hold of the passenger outer tie rod at the adjustment sleeve and rotate the tir rod and it will rotate around in the socket and hitting on the insertion point and make a metal thud sound.

Again, took into shop and they said that would be normal b/c the tie rods have to have that to keep from binding up in front end.

My thinking is that if the tie rod rotates that much, then it is rotating the drag link which in turn puts stress on the pitman arm which in turn has either broken or sheared the pinion shaft inside the box and then when I go over a hole, it moves and all of the above is put into motion.

Shop (Ford) basically called me an idiot and that wouldn't be the cause.

So, now onto my thoughts and questions....
Radius arm bushings
Axle bushings (????? how many and where are they all located)
tie rods and drag links..

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