Hey guys,
I have a very strange noise that I am trying to figure out. I got a 2005 F150 FX4 - when I am turning left and start to straighten out the wheels (so start turning back right) I get a sometimes VERY loud clunk / pop / bang noise coming from somewhere. Pretty sure it is the front end steering / suspension area and would assume so as it is steering related but can't be certain. It is a lot louder / happens more often when I am facing downhill and turning left, so the front end is loaded with weight.

I have had it checked by 2 mechanics, first guy told me the lower ball joints and right outer tie rod need replacing, which I know they do, but he said he is not sure that that would cause the noise as he has not heard that sound coming from ball joints before (I took him for a ride to show him the noise)

Second mechanic said same, lower ball joints, right outer tie rod, but also found that the sway bar is lose which he showed me, and also there is quite a bit of play between the front 4wd axles and hubs, so you can kinda pull the axles in and out a bit more than expected, but was not sure if that is related. He also said he still is not sure where the noise would be coming from based on that list, advised me to fix the ball joints and tie rod more for safety (which I need to do) but he was not particularly confident that that would get rid of the clunk, but it may.

The truck is pretty old and high mileage so just want to keep her running at the moment and don't want to sink $1000s into her especially if the disconcerting noise may not get fixed!

I mounted a gopro and light to take a look a the lower ball joints and outer tie rods on each side and you can see an edit of that here. You can hear the clunk 3 times with the camera mounted on the driver side then 3 times on the right of the truck. All the clunks happen when I have turned left and am either straightening out to the right or have already straightened out. Sometimes there can be a delay after getting the wheel straight and then the noise happening after I go over a small bump or something:


I was expecting / hoping to see some movement in the lower ball joints when you hear the clunks but I don't see anything, same with tie rods. The noise is really pretty loud sometimes and you can feel it through the steering wheel so it feels like something that is taking load and releasing, which makes me think it is unlikely the sway bar or tie rods, most likely the lower ball joints, but both mechanics said they'd not heard ball joints make that noise before, and my gopro vid shows no movement so I am far from confident in that. So I'm a little lost about where the noise could be coming from. Anyone have any ideas??

Also the same noise, at least I think it is the same, happens when I slowly mount a curb with the front right wheel and then drive off it. The clunk happens as I slowly drive off the curb and back onto the road. Doesn't do it on the driver side.

And yeah I know that the 4x4 vacuum line is worn through on the right side in the vid, just found that, so I am gonna try patch the line to fix that too!

Thanks for any advice in advance!

 

Is the video taken with the truck in the air and the wheels hanging? Looks like garage stuff through the wheels. And/or is the truck lifted when it's on the ground (lift kit).

You might try seeing if the clunk is there with the wheels not turning. Do it with the engine off or your foot on the brake.

Also, do the same with the suspension loaded. Truck on the ground.

Could be a CV axle coming unclipped and reclipping in the transfer case. Who knows.

 

Something to consider - take a look at the rear axle and springs. I had a 1993 that made load popping noises when you turned and the problem sounded like it came from the front. I took it to a couple of front end shops and no one could find the problem. Turned out to be a broken/cracked spring support that was within days of giving way when found by me. My issue was in the rear on the left front leaf spring support.

 

BareBonesXL - the video is taken with the truck driving into my parkade where i make lots of downhill left turns. If I turn the wheels while the truck is not moving and wheels on the ground there is no clunk, and there is no lift kit on the truck. If it was CV axle related, would there be any way to verify that?

Jimboy - Ok thanks for the info I will take a look. So in your case it was one of the leaf springs itself that was cracked, or the support it mounts on? And was it easy to see?

May be worth reemphasizing that the noise happens 100% of the time when I drive up slowly onto a curb with the passenger side front right wheel and drive slowly off. The pop is always there as the wheel comes off the curb back onto the road, but it does not happen on the driver side left front wheel.

Cheers

 

Your Question
Jimboy - Ok thanks for the info I will take a look. So in your case it was one of the leaf springs itself that was cracked, or the support it mounts on? And was it easy to see?

My answer
It was the spring support where the leaf spring mounting bolt attached to the support the support itself was riveted to the frame. In my case it was very close to a complete circular crack and was easy to see the tear in the steel support.
Jimboy

 

I checked the areas around the leaf spring mounts and there doesn't seem to be any obvious issues like you described.

BareBonesXL mentioned it could be CV joint related, anyone any idea how I would check that? I'm also wondering if it could be something related the the shocks / mounts too?

Cheers

 

Any luck figuring this out, I have some similiar sounds...

 

Looks like your type of axle bolts on on the inside and uses a nut on the outside. CV axles also have clips inside the joints that hold them together.

The nut on the wheel side could be loose, letting the axle slide back and forth. Or there could be a problem in the transfer case, letting that axle move. Or one of the clips inside a joint could be broken or gone.

Just possibilities based on things that get extended and compressed over bumps. Get under there and yank the CV joint around and see if anything is loose.

Here's a video showing your type of axle. Also shows various other things that can be loose.

 

I did notice something weird in your video. At :30 the wheel seems to be wobbling back and forth. Lug nuts or wheel bearing maybe. Doesn't seem right, the camera is steady as shown by the object right below it.

 

Thanks for the info BareBonesXL, I will get under there and take a look. Just want to clarify a few things you said so I know what I am looking for.

'The nut on the wheel side could be loose' - Which nut exactly do you mean by this? The one that comes through the wheel and that he is loosening at 1:55 in 1aauto the video you sent?

If there was a problem in the transfer case, what would I be looking for to verify that? Is that the part where the front axles bolt onto with the 6 bolts? From searching it looks like the transfer case is further back on the underside.

One thing the second mechanic that took a look said that I mentioned in my initial post is that there is quite a bit of play between the front 4wd axles and hubs, so you can kinda pull the axles in and out a bit more than expected, so that sounds like it could be related to what you are talking about...

Also what you mentioned at :30 in my vid the wheel seems to be wobbling back and forth, I'm fairly sure that is because the camera is mounted on a part that moves independently from the wheel as the suspension moves.

Cheers