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I had my 2001 excursion in the shop numerous times for front end noise on the drivers side. I finally found out, after getting the right ford mechanic, that it was the bolts on the sway bar. They continually come loose and make a very distinct clunking noise when going over any kind of bumps, big or small and when turning. The final answer for this problem was to tighten the bolts with loc-tight. This has been the only solution that anyone has come up with. If they are not tighten this way they will continue to come loose. I have 125,000 miles on this vehicle, since I bought it new 4 years ago, and after fighting this problem for the first 2 years I have not had a problem with these bolts since. I have heard of a number of people with this same problem and no one seemed to know what the problem is.
Also keep in mind that one of the bolts in the sway bar end link is a captive bolt in a rubber bushing. Tigthening the bolt will only affect how it attaches to the frame, but not the slop between the captive bolt and the bushing. The only solution is to replace the end links at about $45 apiece. We were able to isolate this problem on my truck by taking the sway bar off completely. The clunk was gone. The captive bolt will have no slop in the new end links.
Mine is suffering the same fate. welcome to our world. cant we just drive them all to Ford headquarters and throw our keys and payment books through the front windows and be rid of these repair nightmares once and for all?