I have an 03 EB Expedition with 118,000 miles. Told my husband several weeks ago that there was a weird clunking noise that seemed to be coming from under my feet. I don't notice it as much on really smooth pavement. I also have noticed that the ride, that I used to enjoy, seems to be really "Trucky" no offense intended to the pick up truck. At first I thought that the ride change was due to new tires six months ago, tried another brand, didn't get the Contritrac $$$. After reading several threads I've come to believe that both problems could be the ball joints going out. Is this a job for the week end mechanic with a basic knowledge? And, how hard is it going to be for me to talk my husband "(the week end mechanic)" into helping me attempt this? And yes, I plan to help.... He already knows that we're going to be replacing the rear AC parts this week end (clicking noise, no heat just cold air). I've read a dozen threads on this as well. I hope someone can help.

 

Check the sway bar bolts. I had one break and I felt the same clunking under my feet.

 

The original bolts have plastic sleeves and are prone to breaking. I replaced mine with new bolts and urethane bushings.

 

The ball joints on the 4wd EXPY require the dismantling of many of the front driveline parts. I tried it myself and ended up taking it to the mechanic anyway. you have to remove the driveline out of the way in order to pop the ball joint out. The mech charges about 450-500 dollars for the job.

 

Thanks for the info. Decided to have diagnostic done at local tire store. Good news, it was not the ball joints. It needed new links in the stablizer bar. A potential $500 + job turned in to only $180.00 this also included a tire rotation, balancing, and alignment check. Things don't usually go this way for us.....
No more noise. Ride difference is because of tire brand change.

 

I had a similar problem on my '05 and right away thought it was the end links. I tightened them and it went away-for about a week. Then it started coming back. I re-tightened them and it was still making the noise. At this point I was clueless so I took it to Ford and found out there was a service bulletin on the control arms. They replaced both lower arms and problem solved. If the problem comes back call your dealer and ask them about it.

 

Thank you, I'll make sure to keep my ears open. If it starts up again I'll make sure to get it to the dealership.