98 Expe EB 4x4 - I have some play in my steering linkage somewhere and I'm having trouble pinpointing it. I have a dirt driveway. So when rolling thru the potholes at very low speeds there is a "clunk" sound from the front suspension. I also hear it sometimes while turning the wheel in either direction. Its a single "clunk" each time it happens. When I crawl underneath, I can grab anywhere on center link or tie rods and there is slight movement. I believe all that should be tight enough that it shouldn't move by hand. Over the past 2 years I have replaced all 4 tie rod ends (boots were worn). And just a couple of months ago I replaced the pitman arm thinking that was the problem. The "clunk" was gone only for a few days and then it came back. All the boots are in good shape and everything is greased. Is there a way to pinpoint the problem? What should I look for/see/hear at each joint in the linkage? Anything I overlooked? Upper and lower ball joints where also replaced 2 years ago. I'm gonna need an inspection. I know I need rear brakes and new tires. I'd like to take care of this before its inspected. Its hard to find a trustworthy shop. Thanks

 

Loose shock?

 

I had a sway bar link that would clunk, it didn't move when shaken by hand, but it turned out to be the mystery noise. Wasn't at defined times like yours though, it happened randomly over bumps.

 

Give the idler arm a good look. The factory idler arm came with grease fittings that everyone overlooks and therefore they never get any grease.

The best way that I know of for pinpointing any play in the steering linkage is to jack up ONLY the left front wheel. (Keep the right front wheel planted on the ground to provide some resistance in the steering.)

Then have an assistant rock the steering wheel back and forth (about a half turn) while I get under there and place my hand on both halves of each joint. If there is even a small amount of play my hand will feel the play better than my old eyes can detect it.

Good luck.

 

Guys, I checked all of your suggestions. I think the sway bar is the culprit. I can move it by hand and replicate the "clunk" sound. The end links were replaced over a year ago. They still look fine. But I can see that a slight gap in the mount bushings, both of them. As I wiggle the sway bar I can see there's a gap between it and the bushings. Gonna see where I can get bushings around here. I'll post the results.

 

Better late than never. Sorry I never got back to share the results. I replaced the sway bar mount bushings and the noise was gone. Its been quite a few months and no clunk. Also, there are different size sway bars on our Expe's. I had to give the dealership parts guy my vin# to get the right size bushings. He couldn't tell me what size I had. I measured my sway bar with an adjustable wrench and a ruler. I got 35mm.