Thought I would share this with you and maybe save someone the same aggravation I had.

My 2000 had the worn sway bar bushing thump so I bought new bushings and replaced them. Knock was gone and I was very happy. After a short while the knock returned and I was bummed. Had also replaced shocks and springs and steering joints so I figured I had done something wrong. Checked everything again to make sure I hadn't left anything loose. All looked ok. Had a friend stand on the running board and rock the truck while under it and guess what, my sway bar was knocking at the sway bar to drop link connection. Turns out that the bolt at that point has an enlarged shoulder on the head end of the bolt and the hole in the sway bar is larger than the thread end of the bolt. I had turned the bolts the wrong way when replacing the bushings. Turned both bolts around and now the knock is really gone.

Now it's quiet enough to listen for other noises

 

post a pic of this bolt/orientation please

 

I noticed that too. Same deal for me.

 

So, you are saying instead of the nuts on the inside, the nuts should be on the outside?

 

I think that is what he is saying. Look here:

2004 F250 Sway Bar Bushing Replacement

 

My 2002 front stabilizer bar-link's bushings are worn out. Went to dealer and could only get the entire link/bushings assembly (with a new bolt as well) for each side. 2004 trucks can press in new bushings into their links at a much lower cost. Does anyone know if I can use 2004 links, or just press 2004 (or other year) bushings into my 2002 links, or do anything else to make the job less espensive? (The dealer says "no", of course)

 

I have a 2002. I ordered the bushing kit only from Energy Suspension. They offer black and red. I remember reading on FTE that the red has a special blend that prevents noise and early deteriation or something like that.
I did everything myself with the use of a torch and hammer and it was fairly easy.

 

Sorry gang,
Not able to get on the site every day right now. I turned my bolts around so the heads were to the outside to stop the knocking. I will try to get a couple of pictures of them as well as the shoulder in a day or so.

If I can figure out how to post a video I might be able to show you what I found.

We'll see.

 

I too used the Energy Suspension bushings. Neighbor has little press and that's what I used to get the old ones out. Pretty good pop when they let go but like rbsample said, overall not a real hard job.