Hi all,

I am having an issue with my 09 f150 XLT 4x4 with the 5.4 and 180,000 km's (110,000 miles).

I have a pronounced front end clunk which only happens when hitting a "Sharp" bump. By sharp I mean regular road bumps, no noise, but going over icy roads or washboard etc it clunks. When hitting a series of these it almost sounds like a rattle it clunks so much. It sounds like it's coming from front left (Drivers side).This has been happening since I bought the truck 4 years ago. I have looked at it, Ford dealership and a couple smaller shops have looked and no one can find what is causing it.

Work completed so far:
New inner and outer tie rods
New upper control arms and ball joints
New lower ball joints
New stabilizer bar bushings and end links
New lifted struts from Rough Country to replace the leveling kit that was in it when I bought it.
New wheel bearings and hubs on both sides
New slotted and drilled rotors and ceramic pads all around.
New tires and Rims

When it clunks there is nothing you can feel through the steering wheel, in the pedals, or in your *** from the seat. Trucks drives good and straight with no wandering etc.... Only front end part not yet replaced is the lower control arms. I contemplated putting new ones in but the bushings all appear OK, no play in any way.

I have checked everything I can think of to ensure it's not something like my bush bar having play in it at the mounts, right down to rack and pinion mounts and steering rod leading into the cab. Also no where can I see any rub points.

I am running out of ideas here so any input would help.

 

Can you find a bump where you get the bump sound every time?

If so , why not have someone drive your truck over that bump so you can be close enough to get a better idea of just where the sound is coming from?

 

Have you put the truck in 4 wheel drive lately? Also did you check for any play in the CV axle?