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2003 4x4 7.3L crew cab here with mysterious front end noise...
I'm having metallic noise from right front when going over bumps etc. even small ones and can't seem to be able to find source.
I've tried to shake and bang a lot of things there and all ball joints seem fine (this is what I thought would be the problem and still kinda do).
One particular detail; when turning left, the noise is gone no matter how big the bump...
When going straight or turning right, the noise is there.
I've been fighting a front-end noise for 6 months in my 2004 6.0. It was kind of like a groan and I could feel it in the steering parts.
I replaced the ball joints, entire tie-rod and drag link. All Moog parts. I could still hear the noise and could feel it at the base of the steering box. Had the gear box replaced (sloppy anyway) and the truck felt really nice but the noise was still there and I could still feel it at the steering box.
Had my leaf spring bushings replaced with poly yesterday and all the noise is gone!! I have no idea why I could feel this groan at the steering box but the poly bushings fixed it.
It was hard to find because there is so much weight on the ends of those springs that even with trashed bushings the leafs will not move when your looking for it...
Leaf bushings are something I haven't really checked throughly yet, sounds plausible even though my noise is not a groan, but a metal "clinging" noise.
Just replaced the sway bar end link and sway bar bushings on my 2000 Excursion with Energy and Prothane bushings on my truck and all my front end noise is gone. Use to drive me crazy riding on rough roads and banging and clanging everytime I hit a bump. Just wish I had done it sooner.