I just drove home a '97 F250 HD 4x4 with an 8' plow on the front. 200 miles down the highway, the PO advised me against it (he never drove it anywhere but his hometown), but it tracked solid as a rock @ 65 mph. Got 11.9 mpg too!

But the front end has this "rattle" that you hear on the smallest bumps on surface streets, EXACTLY like a loose shock mount, or some other non-life-threatening joint. The ball joints and u-joints and steering all feel solid; I mean, there are no heavy "clunks" when putting in drive, or turning slow, tight corners, or hitting big bumps. But it's a rattling nonetheless, and it definitely happens when the wheels hit small, high-frequency bumps.

Same sound as an old honda Civic I had that needed front struts.

Front shocks are relatively new. Owner is adamant that the ball joints are fine, although he didn't offer any maintenance history to support that.

Happens on bumps, NOT on driveline torque.

What could it be?

 

Brake pads missing anti-rattle clips?

 

Never thought of that. That CAN'T be it. I'll try to hit a series of bumps with the brakes applied and see if it stops just to be sure.

 

My old F350 4x4 had a similar rattle that I traced down to worn sway bushings. Ironic the same problem popped on my new-to-me 2004 Excursion 4x4.

 

That's EXACTLY what I think the sound sounds like, except there ARE NO anti-sway arms, are there?

 

I do not know with your particular setup....a visual check will confirm or deny my theory.