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Could be any of these reasons and more. One thing I don't see is a nut on that shaft so maybe it wasn't installed correctly, looks like it has been rubbing on the opening for a while too so who knows. I don't envy you either way shocks are a bitch to change on these Vans.
Looks like improper installation.
There should be a large washer and rubber grommet on either side of the rusted out hole in the frame. Either the wrong parts were used or it was installed incorrectly.
And it has been getting beat to death based on the visual. That had to make a bunch of noise for a length of time that would exceed the time it takes to drive around the block.
Well, at least half the job of replacing that shock is already done! Some people should not be allowed to own tools. The one's that already do should place a bold label on their tool box reading, "Tools of Destruction"
Rezvani's Latest Post-Apocalytic Monster Is a Ford F-150 Raptor Underneath
Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.