Yup. I've been under my truck for the last week looking for something loose the fix the clunk. Something I did notice is that the sway bar link has a lot of roll to it even though everything is tight. I can grab it with my hand and apply a rolling/torque movement to it and hit metal to metal when it stops. Is this movement normal or are the bushings suppose to hold it thght? Also is there a trick to getting the top passenger link bolt out? Does the frame mount have to come off? The exhaust pipe is in the way. Thanks.

 

disconect the sway bar end links then drive it . if the noise goes away then that is your problem. if it is still there then you know that is not the problem

 

I think i might have the same clunk. Every now and then when i hit the break I get a thunk sound. I have no clue what it is though. Does it happen to you when u hit the break

 

One common clunk is the "Super Duty clunk" - if the clunk occurs when you first take off from a dead stop, it's probably that, and you can find info about in the Tech Folder ("how to fix Super Duty clunk").

If it's occuring at other times, it's probably something else.

Just one thing to check.

 

https://www.ford-trucks.com/forums/7...ing-noise.html

Our issue sounds similar. I still haven't found it. New shocks should be in today.

 

I heard that it could be the end link bushings. But the weirdest thing happened to me. My F250 4x4 has 37,000 miles and I had the "clunk" pretty bad recently. I took the truck to Sears for an unrelated problem; to get the ball joints changed, which they couldn't do for whatever reason. I also mentioned to them that I was hearing a clunking coming from the drivers floor when I would brake hard.

When I brought it in, I had the manual hubs locked. I got the truck back and even though they supposedly didn't do anything, the clunk was gone. I've been driving it for 2 days now and still no clunk. They didn't say that they did anything to fix the clunk. Oh, and the hubs were in the "free" position. I'm not sure if this had anything to do with the lack of the clunk, but I thought I should mention it.

I did crawl underneath the truck just to see if I could see anything. I noticed that there were new cotter pins on all four ball joints. So apparently they at least had the ball joint nuts off. I'm wondering if maybe the nuts were loose or if they had the steering knuckles off and when they put them back on the ball joints were in in a different position. Maybe the clunk was caused by the wornout ball joints, and since they might be in a different position now, there is no more clunk.

Anyway, I know how frustrating the "clunk" can be. So I hope this will maybe point you guys in the right direction. I guess what I'm saying is that it could be worn sway bar end link bushings, something to do with the front axle and hubs, or worn ball joints. It could also be loose steering box mounting bolts.

Oh and I changed my original worn shocks to NAPA Reflex shocks after I got the truck back from Sears. Now the body doesn't roll at all when I make sharp turns. And it doesn't nose-dive either when I hit the brakes hard. It rides MUCH better. This could have contributed to the lack of clunking also because the shocks keep everything nice and firm. Good luck!

 

My clucnk was the endlinks and the bushing of the bar itself. No trick to removing them. There are just pass through bolts. No frame studs.

Make sure you replace the frame mounted bushings though. I did the endlinks first and the clunk was still there. Did the frame bushings and the clunks was gone.

Start to finish it is a 45 minute job.

Be prepared to grunt because Ford used thread locker on the bolts.

 

Disconnected the sway bar and went for a drive. No clunk. Going to NAPA tomorrow for new links and bar bushings.

Check your links.

Cheers.

 

Cool. Glad you figured it out.

 

That's were I got mine.