Apologize for the long post below....

Got a problem with my '95, F150, 4wd, Ext cab, Eddie Bauer. It pops in the front end when making either right or left turns all the time.
It may only do it once when I have it parked and turn the wheels while it is stationary. It doesn't make the popping noise if the front end is jacked up.

List of hardware and parts replaced and inspected.
> New upper and lower balljoints.
(Moog upper, a.c. Delco lower)
>Drop axle brackets ( Installed to correct camber. 3+ degrees with adjustable bushings after Coil spring upgrade)
(Tuff Country 0-2")
>Moog HD Coil Springs CC820
>New Front and Rear shocks
>Moog Outer tie rods
>Motorcraft Inner tie rods
>2" Drop Pitman arm ( I installed this to correct steering geometry)
>New rubber axle pivot bushings
>Reman Lares steering box
>New Axle U-joints

When I replaced the steering box, I don't remember the steering popping, but that was 2 years ago. I did inspect the frame where the steering box connects and didn't see any cracks or signs of cracking in the frame.

I just went through all the installed hardware for the coil springs, the axle drop brackets and the steering box. Some the nuts I was able to snug up a few turns for the brackets, but the coil spring's and steering box were tight.

Truck has been aligned several times and everything checks out ok. It almost seems like tie rods, but they are tight and new. Everything has been greased well.

I even greased the slip joint for the passenger side axle half shaft thinking it was moving and causing the popping.

I can't see radius arm bushings causing the problems, but....theres no clunking from drive or reverse or when hitting the brakes. I have replaced them before on another '95.

Nothing seems to be contacting the bump stops. There doesn't seem to be any showing signs of metal on metal. The rivets on the frame look and appear to be snug.
I did check tranny crossmember. Had 3 loose bolts from my exhaust being installed, but those are tightened.

Coil spring's show no rubbing. Clips for the top are tight along with shock mounts and mounting hardware.

What am I missing??? I'm on the verge of selling it at a lost..

 

Fender bolts tight? Specifically the lower fender bolt. I've had mine come loose and make popping noises. Sounded like front end wear.

 

I thought about the fender, but I can't raise or shake it.

The pop/clunk can be heard very well and sometimes can be felt through the steering wheel.

Keep any ideas coming!

 

Unlock your hubs.

 

Just to be sure, I would recommend you put a wrench on the lower bolt instead of trying to wiggle it. Mine never felt loose. Probably not it, but it can't hurt to check.

Does this truck have sway bars?

 

I checked the hubs, they aren't locked in. I even attached my phone and used the camera to record while driving and turning and the front axles aren't turning.

I will check the fender in the morning.

I checked for play for upper and lower balljoints and there is none. I rechecked the bearings for the spindles. Everything is tight and turns well. There's no slip.

 

Forgot to mention, the truck doesn't have sway bars.

 

Had a chance to check the fender bolts by the hood hinges. They were loose. Tightened them up, but still pops in the front.

Pulled the driver spring and checked everything. Nothing out of the ordinary.

Still popping...

 

Dang.

Door hinges in good shape?

 

both of the 89's and the 87 ive owned, always did this, i never really cared. i always figured it was something in the core support and or core support body mounts, or a crossmember moving

I cant remember if my 84, 85 93 and 97's did

 

My 95 did this until I changed rear spring bushings, sounded and felt like the front but that fixed it.

 

Ironically, I just put new door hinges on in March. Wish that was the noise.

It baffles me for sure. What was weird is that when it's cooler at night, it took longer for the noise, but then it comes back.

I removed the driver side coil spring and shock. I cleaned up the area the spring sits in, used antiseize and greased the contact points where it sits. And I swear, the noise was even louder. It either has something to do with springs or the radius arm bushings. I researched the coil spring's and can't find anyone else that has had problems with them, except for having max out camber. That was the reason for the axle drop brackets and that really helped.

Unfortunately, I work night's and have a newborn. It's rather hard to get much of anything done. I'm hoping I can have my girlfriend help me, its just a matter when we can get time for It.

Hopefully I'll find the problem. I'd hate to sell it. The only thing I haven't tried yet, but come close to it, is putting the original springs in temporarily and see if they are the problem.

 

 

Good point on the core support bushings. I had rotted rear cab mounts that popped, but only during severe flex. They were so bad the frame put dents in the floor pan, also making some bad sounds. Recently, after running a bunch of washboard my driver side axle pivot bushing bolt was loose, I was getting some clunking/clicking from that during turns.

 

Update...

Had my gf help me Saturday. After the power line blew, I was able to do some inspecting. As the truck was parked facing the sun, I found 1 3/4" crack running up and down under the frame support that connects near the coil and shock bucket. It's on the frame the runs from the driver to passenger side, just behind the steering box. With the truck facing the sun, I could daylight through the crack.

I will get pictures and post hopefully and maybe some idea's.