I guess I'll pop the lock-outs out and see if the grinding noise goes away.

 

I had similar problems on my 2000 excursion.

Clunk was sway bar bushings, I couldn't readily find the sway bushings, so I bought and replaced the entire assembly. Still get an occasional clunk, but nothing like before.

Grinding - my grinding was the inner needle bearing in the hub that support the front axle shaft, right front like yours. Of course ford does not sell those separately, they will just sell you the entire hub assembly $350 - $400. I measure the needle bearings and started calling around. Found replacements for about $10.00 local. That was two years ago, all has been well since.

 

Well, I found the grinding noise. I finally got a chance to take it apart tonight. My guess is I've got a stuck caliper as well. Can you get caliper rebuild kits for these, or should I just get a new caliper? Luckily, it's on the rear, so not a huge deal. I guess the guy that inspected it last month didn't really look too close.

 

In PA he only has to check one wheel in front and one in back. Moreover he is looking at rotor condition and pad material left. Not looking for a stuck caliper. He is looking to see if it is safe only. Brakes need to be 2/32 on bonded and 1/32 on riveted. 2/32 on tire tread as well. A stuck caliper could go under the radar for sure.

 

I don't think there's any chance there was adequate brake pad material when it was inspected. I don't know how many wheels they're required to check, though. Probably two.