Thanks Wheelman, I'm working on the list of potential noise making items that you provided me. I have her in the air and from underneath, haven't found anything as of yet. I'm sure something will come to the surface, since I have noticed the noise or sound is changing when there is a change in the road elevation and I'm turning to the right. You would think I would be able to recreate the noise as well, but so far, nothing.

I will continue to post updates if I have any new insights or potential causes for the noise. If anyone has suggestions.....I would love to hear them.

 

I had a clunk in my 90 250 when I went over rough terrain or turning out of my driveway crushed concrete. Anyway what I found was a broken motor mount the mounts have a retaining pin to keep them together so when it went bad and I was going over the stuff best I can say is that the motor was flexing and hitting the end of the pin and clunking.

 

roboto65's commit reminding me of a clunk I once had,never seemed to happen in the same place twice but usually while turning or stopping.
while greasing the u joints,I discovered the trans mount to be bad,no clunk since it's replacement.

 

Thanks Robert, I will definitely check that! What did you find bad? The structural member that runs side to side or the rubber isolator between crossmember and trans?

thanks, Robert.

 

Thanks Roboto, I would never have even considered the motor mounts. The truck has a 4.9 in it and I know when I have had the hood open and started her, the 4.9 should moves around a lot until it starts but then settles back comfortably. How did you ever find that? I didn't know there was a pin even there.
Thanks for the info...I will take a look.

 

I'm curious about my tie rod ends. With the front end in the air, both wheels off the ground, I get no movement when I try and rock the wheels from side to side. (Hands at 3 and 9) When I craw underneath and grab ahold of the tie rod link, Drivers side, and try and get vertical movement, i don't feel any. When i try and move the center tie rod from left to right or across the vehicle, i Still don't sense any movement. But if I try and rotate the assembly, it rotates fairly easily. Is that an issue? Should I be able to do that? Is that an indication of excessive wear? If so why no vertical or side to side movement. Appreciate any knowledge someone might be willing to share.

Thanks in Advance!!

 

Yeah well I have to confess when I rebuilt my motor I knew the motor mount was bad LOL I just put it on the non torque side I thought but when I pulled it it was obvious and the pin was holding it together maybe a safety feature.

 

I'm still chasing a problem/noise on my 96 f150- 2wd. I'm trying to find the torque values for the tie rods, both outers and the two inners, as well as the attachment to the Pitman Arm and adjusting sleeve bolts. But I have found nothing specifically for the old Ford's new suspension. If any one knows where I can find the torque specifications or have the information and be willing to share it, I would greatly appreciate it.

 

The torque values should be in the service manual. You can find the manuals on eBay for sale and sometimes at your local library to use and make a copy.

I recommend getting a set of the three manuals: service, body and electrical.

 

See photos

 

Thanks Mark that was a big help. I actually have a Chiltons for this truck, but loaned it to a friend so he could work on his 93. Now, he can't seem to locate the Chiltons. So your response was very timely. I was in the final strokes of putting her back together and had no available source to get the torque values. I appreciate it.

I got her all back together. Just finished a few minutes ago. She is resting comfortably in the shop. Tomorrow will be a big day, her first road test. I have found a lot and done a lot. I will post results tomorrow, if I have fixed her.

For someone reading this and needs the torque values for the tie rods on '96 F150, Here is what I used:

Tie rod ends: 60-70 ft lbs.
Tie rod Adjustment sleeve : 35 - 40 ft lbs.

Thanks again for your help.

 

Glad I could help. Hope the road test goes well.

FYI you can buy a CD with the Ford OEM service manuals on RockAuto for about $25 (https://www.rockauto.com/en/moreinfo...14583&jsn=1256). They are extremely thorough... probably 3000+ pages of information and way more detailed than a Chilton's or Hayne's manual. Another great source of info is Steve83 on supermotors (https://www.supermotors.net/users/Steve83) ... I'm not sure if / where this guy is still active online but he's archived a lot of great information. Hope this helps.

 

Lubricate any rubber bushings that maybe rubbing on metal surfaces. Like Shocks bushings, shackles bushings, frame to cab bushings.

 

Good point! What did you use as a lubricant! Silicon?

 

Drivers Side Axle Pivot

Passenger side Axle Pivot

OK, If you have been following this posting regarding my search for the crack, pop or knock that comes from my 2wd suspension on my 96 F150, I can provide a bit of an update. I have all new tie rod ends, including outer and inners as well as both adjustment sleeves. They were quite loose, especially the inners, both of those could be moved easily by hand once out of the truck. The truck drives so much better, very tight and responsive.

Yet when I make a right hand turn, I still get a metallic knock. So above you will see pictures of the axle pivot bushings. The one side looks bad for wear and is cracked and looks like a piece of the rubber isolator has actually chipped out. However, I would assume based upon what I have read if i try and pry the axle up or down I should get or see some obvious movement. I get no movement that I can see. I used a 4' long crow bar and I can see the body lift both no movement in the pivot bushing. Is there another way of testing to determine if its as bad as it looks?

Also, I'm looking at this thinking I should be able to change out the axle pivot bushings without removing the axle assembly. I looked at a Haynes repair manual, not much help there!

Mark, thanks for the Link regarding the OEM service manual at RockAuto. Unfortunately, according to some emails their cd will not address my 96, only up to 95. Many items are the same but many different as well. If you ever see a 96 manual there, please let me know.

I look forward to hearing anyone's thoughts or recommendations. Thanks in advance.