Vehicle is a 98 E150 with 135k miles. I have a weird clunk feeling in the steering wheel, but there isnt an audible sound with it. This only occurs when the van is under 20 mph and steering wheel is turned. Its intermittent and it does not happen every time, however its enough to be kinda annoying. It happens more often on uneven surfaces such as when pulling into an inclined driveway. Happens in drive and reverse.

Parts I replaced:
Intermediate steering shaft
Front struts
Sway bar mount bushing and end bushing
Wheel bearings, pads, and rotors

These parts needed repair anyway but thought it would help eliminate the clunk.

I took a pry bar to all the joints and greased them up. Nothing stood out. Greased the driveshaft slip yoke and adjusted the steering box didn't help either. I work on all my stuff but this is my first time owning a bigger vehicle so I'm not sure what else to check or what it could be.

 

Did you check the idler arm on the pass side of the vehicle?

How was the condition if the U Joint on the strg shaft?

 

The old steering shaft u joints had some play but the new one I put in doesn't. My van doesn't have an idler arm on the passenger side.

 

I was digging into it more today and noticed the shaft coming from the top of the steering gear box where the intermediate steering shaft connects has very slight play. If I grab the bottom of the intermediate steering shaft, I can forcefully wiggle the steering box shaft side to side. No up and down movement. It's very minor play but could this be the culprit? If so, would tightening the steering box a little more help?

 

There might be some wear with bearings inside the steering box.. Consider replacing it or have a good shop it out.`