I just did the same thing last week. New XRF ball joints, new hubs, new sway bar links. Still making the clunking noise. Does anyone know of what the size of the sway bar is for the bushings? Thanks. I'm ready to drive this thing off a cliff.

 

We recently purchased a 2002 2wd V10 100k and also have a clunking feel/noise in the front end right under your feet. It happens more often when going thru dips in a turn. At first I thought it was radius arm bushings (we have 3 1st gen Explorers), but after dropping them to take a look they seem fine. I have already replaced the shocks and installed a Hellwig front sway bar which came with new main bushings, the end links look fine. I tried twisting the steering linkage, it was stiff and not smoothly rotating the joints. After greasing the joints they twist better, but still have rough spots. Will test drive over the next few days.

 

Disconnect the front anti-sway bar and drive it like that for a while. I do this during off road trips for the extra suspension travel. See how it feels to you on the road. That will confirm the 'sway bar' source of noise. The bar will droop down, but won't be in the way as you drive.

 

Sean, wtf is up with that sway bar mount?

I had the wife jumping on the drivers running board and was able to see the sway bar moving and clunking. What size are the bushings?

 

I just used the Moog Sway Bar Bushing Kit from Advance Auto and greased them up good.

Part No. K80203

Very cheap fix, but like I said previously, I'm not sure if it was the end links or the bushings specifically because I replaced both at the same time. I'm just happy the noise is gone.

 

Back in 2008 during an off road Excursion, I did some remodeling down there. Some great memories looking back at the pics.


Broke the entire mount off with a boulder. Decided to upgrade to steel bar. No complaints since.




edit, found the video.

 

I used these Energy Suspension 4.5180G Front Sway Bar Bushing Set 16.xx at Amazon. Not sure if there is a difference in sway bars..as we have different years.

 

I finally found my noise. It was my front sway bar bushings. They were shot. I bought a new Hellwig bar and used existing end links. I now have a noise in a bushing somewhere up front.

 

What exactly was worn out? The metal sleeve, rubber missing,?
Any pics of the worn parts so we can see what to look for?

 

Just got the same kit yesterday. Sort of installed them. They are way to small. Either way, with a generous amount of grease, I drove it up the street. STILL HAVE THE CLUNK!!!!!!!!!!! If I rock the truck hard left to right, I can hear it. Just can't see it. Really starting to hate the truck.