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Could it be the leveling of the sway bar? maybe i didnt have it at the right angle?
The swaybar should be level. I don't thnk the rear swaybar is the problem.The swaybar does not allow the body to roll if the rear wheels are on level ground and the front on uneven ground. Thus, excerting more torsion force on the front swaybar assembly. Which I have been told is hollow and will flex more than the rear. A loose bolt in the front can make noise as a result from the rear swaybar torque. This really sounds like what I went through. Be sure to let us know what the final fix is.
Well i checked all the bolts up front and there was nothing loose. I still tried to get a slight turn out of everything. The resolve to the problem was to drop the bar a little from where i started and to my surprise no more popping!! here are some pics to try and help anyone else that might have this problem. https://www.ford-trucks.com/user_gallery/displayalbum.php?&userid=1438&albumid=1562 I think in about a week after driving the truck i might try and move the bar up one notch to level the bar slightly and see if the popping returns if it doesnt then i will replace the pics with new ones. I want to give a big THANKS to all that help me with this problem and i hope to return the favor one day.
One of the response indicated that the rear sway bar MUST be level. I had a similar problem. Installed the sway and had a clunk in the front end on accel and bumps. Leveled the rear sway and no more noise. It's worth a check to make sure the rear sway is level or at least parallel with the frame.
What locations do you have the bolts on the bracket that connects the bar to the frame. Check the pictures i n the link to see where the bolts are on mine
When i first installed the bar thats the way i set up the links ( The way you have yours installed). which in turn caused the noise in the front. I am going to move the bar up one more notch so that it will bring the bar almost to the level point to see if the noise comes back. I think since i replaced those crappy stock shocks with the Edelbrock units that might have made a difference also in contributing to the noise.