Front end clunk solved!
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5th Wheeling
Joined: Oct 2016
Posts: 34
Likes: 0
From: Eatonville, WA
Front end clunk solved!
We bought a 2005 Excursion about 9 months ago and it has had an occasional clunk in the front end for quite a while. Mainly when turning and either accelerating or going over bumps. The strange thing is that it would sometimes get worse, then get better for a while, then worse, etc. I replaced the sway bar end links and bushings, but that didn't fix it. I had it looked at and my mechanic couldn't find anything wrong, so I took it to a Ford dealer in truck country. They spent a while with it and couldn't find anything until I took them for a test drive and miraculously made it clunk with the mechanic in the truck! They then diagnosed it as a bad leaf spring shackle. Replacing that fixed it! What a difference. The truck just seems rock solid now in a way that it didn't before. I just thought I would pass this along as it wasn't easy to diagnose.
Fleet Mechanic
Joined: Feb 2011
Posts: 1,812
Likes: 88
From: Thousand Oaks, CA
Ours has had a couple of thunks in the front end.
I upgraded the front sway bar and its' bushings with a Helwig so that wasn't the problem.
One thunk occurred going thru dips in turns was the left outer tie rod end.
I've been replacing the tie rod ends one at a time.
There is another thunk going straight over speed bumps which may be the right inner tie rod end (last one).
Mountain Pass
Joined: Jun 2012
Posts: 193
Likes: 34
From: Upstate, SC
My 2wd has a clunk in the front when turn sharp and rolling. Like pulling out of a tight parking spot. Tie rods are tight. I've replaced the ball joints and rear bushings on the radius arms. Still there. I think it is going to be the inner bushings of the Ibeams. Just haven't taken the time to go there yet.
Fleet Mechanic
Joined: Feb 2011
Posts: 1,812
Likes: 88
From: Thousand Oaks, CA
We bought our 2002 with 104k and the front end was making thunks, but it was difficult to pinpoint where.
I replaced the shocks (they were toast), new front sway bar/ends (for towing), trans mount and just finished all the tie rod ends.
The tie rods ends definitely fixed two of the noises.
I think the thunk was difficult to pinpoint because there is still a 3rd.
It makes a soft thunk, but not very often.
The first 2 tie rod end related thunks happened very often.
The radius arm bushings look fine and I was wondering about the ball joints.
I looked at the inner I-beam bushings and one looks not quite centered.
Please let us know how it goes with yours.
Fleet Mechanic
Joined: Feb 2011
Posts: 1,812
Likes: 88
From: Thousand Oaks, CA
Update: Found the 3rd thunk.
When we bought our Ex there were thunks in the front end.
One of the first things I did was install Hellwig anti-roll bars, rear leaf springs and shocks.
New tie rod ends fixed 2 of the thunks.
The 3rd was being caused by the rear anti-roll bar install.
On the left side I had installed the bar connecting rod to the frame with the bolt facing inward.
The rear leaf spring would hit or rub the end of the bolt causing a thunk that sounded like it was under the driver's seat.
Reversing the bolt to face outward has eliminated the noise.
Weird how the sound traveled thru the frame to seem like it was the front end.
I read another post how someone had a similar issue with a loose rear anti-roll bar mount causing a sound that seemed to be in the front so I checked mine and found the worn bolt end.
When we bought our Ex there were thunks in the front end.
One of the first things I did was install Hellwig anti-roll bars, rear leaf springs and shocks.
New tie rod ends fixed 2 of the thunks.
The 3rd was being caused by the rear anti-roll bar install.
On the left side I had installed the bar connecting rod to the frame with the bolt facing inward.
The rear leaf spring would hit or rub the end of the bolt causing a thunk that sounded like it was under the driver's seat.
Reversing the bolt to face outward has eliminated the noise.
Weird how the sound traveled thru the frame to seem like it was the front end.
I read another post how someone had a similar issue with a loose rear anti-roll bar mount causing a sound that seemed to be in the front so I checked mine and found the worn bolt end.
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