Help diagnosing clunking suspension noise

TheDoug · Nov 17, 2023

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 · Nov 17, 2023

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 · Nov 17, 2023

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 · Nov 17, 2023

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 · Nov 19, 2023

Deadman said:
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 · Nov 20, 2023

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 · Jul 24, 2024

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 · Jul 24, 2024

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 · Jul 24, 2024

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 · Jul 24, 2024

apex96 said:
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.

Help diagnosing clunking suspension noise

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