Clunking noise

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Dec 17, 2017 | 10:36 AM

johnsonjf

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Tuned

Joined: Jul 2013

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Clunking noise

Good morning,

I have a 2004 Excursion 4x4 with a 6.0 PSD. I’ve replaced all the ball joints and steering components, sway bar links are also new (on the front), made sure everything is tight. I am starting to hear a clunking noise when I go over bumps, the noise is coming from the front and back. I am thinking it could be the leaf springs in their shackles wearing out the bushings. Any thoughts on this? I’ve looked into replacing all of the bushings this week.

Thanks,
Jeff

Dec 17, 2017 | 10:43 AM

A Rodder

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Possibly spring ends rubbing on the shackles or body mounts.

Dec 17, 2017 | 11:36 AM

fordboy67

Cargo Master

Joined: Dec 2007

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From: Minnesota

I see you said sway bar links are new, how bout the sway bar bushings? I had a pretty loud clunk that replacing these took care of even though visually they looked ok. Just a thought! Good luck!

Dec 17, 2017 | 11:48 AM

Nicmike

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Joined: Feb 2012

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From: Western AR

Jeff, you are on the right track. I have same issue, and I just upgraded rear springs and bushings recently (mod B springs with Energy Suspension bushings). Clunk in the rear is now gone, and I only have the clunk-in-the-front left. Front axle and leaf springs will be gone soon, so that should be resolved then.

Dec 17, 2017 | 03:12 PM

johnsonjf

Thread Starter

Tuned

Joined: Jul 2013

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I’ve been looking at different bushing sets. Is there a difference between the black, blue or red Energy Suspension bushings? Looking at blue Moog sway bar bushings. If the weather will cooperate I hope to have all of them in on Wednesday.

Thanks
Jeff

Dec 17, 2017 | 06:05 PM

Nicmike

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From: Western AR

I went with red. I think they are all poly material regardless of color if buying from Energy.

Dec 21, 2017 | 05:50 PM

johnsonjf

Thread Starter

Tuned

Joined: Jul 2013

Posts: 268

Likes: 2

What a job from hell. Replaced the first leaf spring bushing on the front, took 2 hours to get the old one out. There has to be an easier way than using a drill and hammer, any suggestions? I also replaced the front sway bar bushings, those were simple.

Jeff

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Dec 22, 2017 | 04:04 AM

Watcher58

Laughing Gas

Joined: Nov 2014

Posts: 1,108

Likes: 23

Front is probably the body mount ( aka Ford Part No.: 2C7Z-1000154-AA
Insulator ) in the #2 position. Ford conveniently discontinued the upper part but you can still get the lower which is absolutely ludicrous. These are the only 2 insulator parts (LH and RH) I see that are discontinued. Strange how they no longer make the crappy one.