I purchased a 2" Ready Lift Kit (strut spacer) for my truck and had a local shop install it. The truck drove great all yesterday and this morning but this afternoon some noise started to develop. It a rattle sound and sounds like something is going to break off. The thing is, it doesn't really make noise going over bumps but starts to develop sound when traveling at higher speeds on the freeway. I checked all bolts I could, some I was able to give some more cranks with a ratchet. That seemed to have cured it when test driving in the neighborhood but after 5 mins driving on the highway it slowly started to develop and go back to the original sound.

What the heck could it be? I am obviously not able to check the strut to spacer nuts as they are tucked into the frame perch. The truck has 200 miles and it is a 4WD.

 

Possibly 4x4 actuator issue? Where are the actuators to lock the hub? It sounds like it is coming from the Hub and possibly the hose didn't get hooked back up and 4x4 was trying to engage at detain speeds..

 

Does the noise go away when you lock it in 4x4?

I saw someone else on here had a problem with the upper control arm hitting the coil spring. Check that?

https://www.f150forum.com/f118/readylift-2-5-installed-knocking-sound-295999/

 

I haven't tried but the truck likes to make the sounds at somewhat higher speeds. It will make the noise not even going over bumps?

 

This sounds very similar to what I just dealt with:

Possible IWE Failure

The biggest clue to finding if this is the problem is to switch to 4 wheel drive when sound begins. If the sound goes away you have a vacuum loss issue. Which means it is probably a bad solenoid, IWE actuator, or vacuum connection/line.

 

My 4x4 works great and didn't really hear a difference between the two. The rattle is virtual gone when the car is cooler in temperature but if I start driving it for 10-15+ minutes it starts. It's definitely a rattle of some sort. Here's a video, I know it's not the best but you can hear it at some points.
There's a lot of wind noise but you can hear it at 19 and 27 secs

 

The shop redid the lift and put lock tight on all nuts and bolts and torque them however I can still hear it rattling noise somewhere out of the car and don't know what it could be.

I talked to ready lift and they said there is no issues with using the 14 model kit on a 15 but I would get a full 2". I can hear the sound when switching the car back and forth. It's sounds like a bad wheel on a shopping cart

 

Truck is at the dealer. They went for a ride and immediately said the shop over tightened the hub assembly and prob broke a piece in side. It will most likely not be covered under warranty and I got a feeling that shop is gonna be a jerk about it

 

My guess would be the plastic piece in the IWE. Hopefully the installer will cover it, They probably will.

 

Do you mean the wheel hub? The shop that installed your lift kit?