The stock bolts are cut down too far for the upper sway bar link mount so they fit way too loose in the upper frame mount and the last 3/8" of the bolts are stepped up and fits into the link bushing OK but doesn't support the whole length of the link bushing. The whole thing is a mistake by Ford. They stepped the bolts up near the head so they will fit into the bushing without having the press the full length through the upper frame mount. The only fix is to drill everything out and use the next size up bolt and tap it into place the full length or you can take the McGuyver route and fill the void in the cut down section of the bolt with fiberglass fibered (or other strong tape) tape or smear some JB Weld onto the cut down section, let it sit overnight, and then smooth it with sandpaper and a drill to fit. I used the tape and it is very quiet now. Tightening to the max is not the answer because it is only the small inner faces of the nut and head that are making contact and they will loosen their grip as soon as you go off-road or get on a bumpy road. You really need to take the upper bolt out to see what the problem is. Also the bolts that came with my new complete end links were only slightly improved. The stepped up part was longer and thicker so it only helped with the fit into the bushing which was never the real problem to start with.
Look how much room there is in the bushing and the frame mount hole is the same size.

 

Thanks. Same as as you just covered here right? https://www.ford-trucks.com/forums/1...ew-thread.html

 

Pretty much but with a few more new ideas.