It finally got to me, I couldn't take it any more !! Looked up the instructions, with pictures and shot an order to Clay at Riff Raff. The yellow box came and I went to work on it. Really not a bad job and only took a couple of "slow working" hours to do. Now........ I can turn the radio down and quit explaining "what is that rattling?" to my passengers. Sheesh ! Should have fixed it months ago.

If you got the clunk, fix it, it's not that bad and worth the money and effort. Here's how :

2004 F250 Sway Bar Bushing Replacement .: Articles

 

One of the first things I had to fix on my excursion, saved lots of time by looking at FTE threads for sure.

 

Need to do this to mine... also going to flip the brackets for the swaybars where they bolt to the frame. Mine are pulling up on the sway bar itself all the damn time!

 

New end link bushngs, new spring tip isolators (TSB 99-16-3) and slip yoke lube (TSB 05-6-10) and no more squeaks, rattles or clunks.

 

Payson, you got a stealth bomber ! So far I'm quiet in those places.

 

Could that be the clunk I hear when I brake for a stop with my 01 F350 FWD ?

Smokie

 

My early 99 didn't even have spring tip isolators, let alone worn out ones.
That made for an easy diagnosis of the front end squeak.

 

Nice work Bob -Thanks for the pic's

 

why could you not just put a grease zerk or 2 on the slip yoke? I figure if you put 2 opposite each other that would be balanced. I have had other vehicles with them on the yokes. anyone?

 

I need to pull mine back apart this spring and hit everything with some WD-40. It started pouring rain just after I started and I ended up installing it all in 4" of water. Now it freezes every time park then pops loose first time it moves. It is worse than the rattle was.

 

Reps sent! One piece of advice from my experience, replace all the bolts as well. Mine had obvious wear on them and were contributing to the clunk.

I didn't know about the tip isolators - I'll be looking at it today. I tried to Rep Payson, but I'm in Rep jail.

 

Bob: Sorry for hijacking. but i need to ask Payson if the spring isolators will work on 2003

 

No hijack problem with me buddy ! I didn't do the pictures and write up but like you I was greatful for them. It sure helps when somebody has gone to the trouble to document and photo a job. This forum is full of that kind of stuff and we all benefit from it when needed.

The clunk while braking could possibly be swaybar or end link bushings or it could be something else. Somebody might chime in with a suggestion for you.

If you get under your truck and wiggle the end links and the swaybar they should be hard to move and little or no play in them. Mine was so shot out that I could move them around a lot. I also suggest that you make arrangements to have access to a press to get the old bushings out. I know some folks have hammered them out but mine wouldn't have come out without the press. Oh... and safety glasses under the truck. Mud, dirt, grit etc. will make you wish you had them. Don't ask me how I know !

 

Since we're talking about bushings, where are you guys purchasing these things?

I recently purchased a 2001 F250 SD 7.3L with only 59,500 miles and the suspension is still pretty tight. However, the more I drive it, the more I'm starting to notice "sounds."

BTW, I do all of my own work and I do own a hydraulic press as well.

 

Could be, but you should jack up the front end and test your ball joints. That was what 'my' 'clunk' was..... ball joints.