Ford Super Duty (1999-2016) :: Front End Clunking And Binding Sound Like A Sledge Hammer Bouncing
Sep 10, 2013
2002 F250, 8 inch lift w/ 37's ... Manual locking hubs ...
Ok so my truck has no issues in 2wd even with hubs both locked or when in 4x4 hi/ low with hubs UNLOCKED.
BUT as soon has 4x4 system is in action as I idle forward there's a massive clunking and binding sound like a sledge hammer bouncing off my front diff./ drive shaft. But there's no physical binding of any components that I can see! Just a rhythmic and consistent thumping.
When you turn the wheel either direction the sound intensifies. I even dangled from the side steps as my buddy rolled forward to observe the situation.
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My 11 cc lb 4x4 6.2 has a clunking/loose sound coming from the front end. It is prominent when going over small/medium bumps but not so much large bumps. I have had my local dealer and a couple local shops look at it and they all say everything checks out. It definitely seems like something is loose in the front suspension. I just put new Gabriel max control shocks on all four corners. I have no play in wheel bearings or ball joints. Tie rod ends also look fine.
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This is the first winter I'm driving my truck. I put it in in 4x4 HIGH the other night due to the snow (and I wanted to check out everything).
Seemed to work fine until I was backing into a parking spot doing a full lock turn. It didn't seem to move. I gave it a little more throttle and it "released" like it was stuck or going over an obstacle. Happened again when I did a full turn backing into my driveway (this time turning the opposite way).
It seems to work fine going forward with tight turns. Also and it doesn't "bind" in 4x2 mode. I haven't tried 4x4 LOW yet ... I guess I don't want to wreck anything if it's not operating properly. Is this normal?
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I have a 2008 F-450 Lariat 6.4 4x4. I recently started noticing the front driver side wheel (best I can tell) wheel makes a noise as though it's binding uo when turning either direction, and I can feel it as well. 4wd is not activated and the hubs are in auto. When the front end is off the ground, I rotated the wheels and they spun independently unless the hubs were locked. I noticed what appear to be seals on both the driver and passenger side hanging loose (see pics). What this might be? I recently used the 4wd when we visited White Sands National Monument while pulling a 5th wheel RV.
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I have a loose, binding, metal on metal sound on my steering wheel shaft. I have removed the steering wheel, replaced the clockspring, because when I removed wheel clockspring was in pieces and I thought that might be the issue. Guess not, because I'm still having problem. Other than having to remove or replace the whole steering column...
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Have an 03 f250 6.0L and the tie rod from pitman arm moves easily and there isn't a steering stabilizer, noise got worse after I put new tires on front but it's a loud clunk that I can feel. I've replaced the sway bar bushings and end links. Would the worn tired rod make that noise or would it be ball joints?
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So I noticed the past few days my 09 F250 was clunking in the front end when turning hard even with the hubs in auto so I knew there was an issue in there somewhere. This morning I took the jack and found the passenger side would not release no matter which way the lock was turned. Pulled the locking assembly out and found a couple of the pieces of plastic cage broken (truck has 250k miles) which is to be expected I guess but the locking ring that holds the inner piece that slides over the axle stub was off and hanging next to the c-clip on the axle.
So with the plastic of the cage already being broke and the mileage on the truck it's clear I need a new lock for that side.
Here's my dilemma, I have to deliver a conference room table 200 miles away tomorrow morning that they need for meeting tomorrow afternoon at 3:00pm. I cut the rest of the plastic pieces and took the gears out leaving just the cover with the diaphragm and put it back on the hub. I can't come up with any logical reason why I can't drive the truck this way but just want to bounce it off the experts here before I take off on a 400 mile trip in the morning. The only thing I can come up with is if I were to engage the 4wd the vacuum might suck the auto-lock diaphragm in and pop it but otherwise I can't find any reason to not run it this way, the hub is still sealed up and free-wheeling just like if it were in 2wd anyway.
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So, I have this problem that comes back when the temperatures drop below about 20 degrees F. The truck is a 2012 F350 diesel with 15k miles and has done it since it had 3,000 miles on it. When turning in an intersection, or just moving the steering wheel left to right, it makes a clunking sound up in the front steering area and you can feel it a little as well. I have taken it to the dealer and they tightened the body mounts, but that did nothing. Once it warms up, the sound is gone.
This, coupled with the rear end clunking loudly over every bump and pothole when it is cold out, makes this truck a real noisy/annoying vehicle in the winter.
Here is a video of the steering noise, it is louder in person: [URL] ....
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2012 truck, started making a noise today. I cannot tell what it is, but seems to be coming from the passenger front suspension, its a crunching/light clunking sound, happens when going over bumps, when the truck pitches one way or the other turning, and coming to a stop....
Truck has 6k miles, I did a quick visual inspection this afternoon, didn't notice much, but the sway bar endlink looked a bit odd though, not sure if normal, its gota little bend too it and seems to just contact the vac line mounted behind it, seemed unusual...
Maybe its its just one of the crappy rancho branded shocks is junk?
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I thought there was a v10 specific superduty section like how the psd does, but my thread went in the "performance, engine, troubleshooting" section.
I wanted more exposure than that particular small viewed area.
I don't have a video of the noise, but my 99 f450 v10 5spd has some iffy noise coming from the front. I've read so many threads on this and they either end with "my motor had 1-2-3 bad pistons" or "my flexplate was cracked" and all that dealt with chain tensioners were never finished.
I know what piston slap sounds like (worked on many cobras and lightnings with forged pistons that had it) and have experience with bad wrist pins and broken piston skirts, and this noise doesn't sound like any of it.
Noise is a loud clicking/clunking/Detroit diesel idle noise. When you rev the engine up it doesn't lighten or get better, only worse as rpm goes up. Oil is terrible looking, I'll be getting that changed this week.
Story on truck. I've had this thing for 4 years with blown motor. I got a buddy that acquired a parts truck and he said it ran good. I dropped my truck off and he swapped the engine. I got my truck back running, but with this engine noise. He said it needs to get run some more and change oil.
I think it's timing tensioners, my buddy says it will come out of it, a mechanic friend says it's going to blow up "because they all do" and I don't really want to replace the engine again.
If it's tensioners, how big of a job is it. I have the cam clamps and crank stop and the ford tools to make sure crank and cams don't rotate while apart.
I'm just 650 miles from my truck and may need someone else to do the work. Which sucks.
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With the tranny in neutral and clutch out is when it is the loudest. With the clutch in their is 0 noise. The sound is a spinning clacketing sound best I can describe. The clutch is 2yrs old and was installed by a local shop using all OEM parts, the fluid level is perfect and looks brand new. The sound has come on gradually over the past 6 months but now can be felt thru the floor at the top of the gears as a rumble. The funny thing is that their are no performance issues like grinding,popping out of gear,hard shifting,etc.
This is not rolling gear mesh it is very loud clacking clunking sound coming directly from the tranny, not the transfer case, nor rears or u joints. This is standing still. Sometimes it will be a little less loud if I roll to a stop in neutral with the clutch out as opposed to gearing down to a stop push clutch in goto neutral and letting clutch out.
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My front driver side wheel is making a clunk noise when I hit a bump. I replaced the wheel bearing hub assembly and discovered both axle seals were bad.
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So to start at the beginning.... Traveled across Canada East to West towing 11000lb travel trailer, no problem. Have used 4x4 in a few campsites to pull out of a pitch without spinning the wheels and causing damage to the site when it has been really wet. All good.
Got to Banff in December and the town was an Ice rink, engaged 4x4 and all good. Crossed the Rockies and the 4x4 starts making grinding noises. Up and down some mountains and squeaking, grinding noise then clunking.
I have manual hubs, disengage and the noise all goes away. Engage 1 hub and no noise. Engage both hubs, noise back.
I bought some needle bearings and went to swap them. Got hubs apart and they look good. No scoring on the drive shafts. They are not dry, but as I have them open, repack them with grease anyway.
Do more research... Remove ABS sensor and repack main bearings with grease. (broke one sensor pulling it out, too cold plastic brittle oops). Still clunking noises.
The universal joints look good, doesn't appear to be any play in them. However, the axle seal (knuckle seal) (F81Z-3254-CB) does move around a lot in it's metal casing. It is tight on the shaft, but with the hub off, I can move it in and out, and move it side to side. If I had ESOF hubs I guess they would not be locking as I'm sure there would be no vacuum in there!
Question is then, would this seal be allowing the universal joint to wobble under load in 4x4 mode? Would this wobble be the cause of the rumble? As it is labelled as a seal and not a bearing, I wouldn't of thought this would have been a loaded point, and the weight would have been taken by the associated bearings and it could be run without this seal? But if it is not this, then I'm still looking for a clue as to what is making the rumble....
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I bought a 2000 F250 V10 Super Cab. Oddly after a few weeks it has grown on me. There has been a clunking noise out of the right front over bumps. I traced it to a bad axle bearing. The u joint moves up and down about a 1/2 inch. Besides pulling the hub/bearing assembly out and removing the axle are there any surprises getting the old bearing out?
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Got issues with speedo bouncing back and forth after going over 80 km an hour that and under is steady changed speed sensor replaced speedo with another had read about sensors brands not working with speedo unit had put Napa brand in so wondering if it's just the sensor...
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I bought a 2004 F250 Crew Cab LB 4x4 with the 5.4 Motor and when I turn left it has some Tight Spots and I can't figure out why, I checked the Drive axles to make sure the locking hubs were unlocked and they spun freely, I Also have a lot of play in the steering wheel, Could this all be Related to the Steering Box? What else should I check for ?
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My 2005 has the ESOF system which has worked flawlessly. Recently I had upper and lower ball joints done and after that repair I had no auto locking hubs. ( independent shop messed up seal install ) they redid the job and it now seems like my front hubs are locking automatically because I am getting binding while turning. So this is the problem.. the front wheels do not "pull" only the rear wheels spin. If I manually lock the hubs I have 4x4 and can get out of being nearly stuck and everything works normally. What is wrong here? Does the shop need to redo the job again?
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I replaced the steering gear box in my 06 F250 CCLB 6.8 over the weekend with a reman Cardone. The old gear box had what I can best describe as a chatter/binding if you rocked the wheel back and forth, that's gone now. I sucked out as much fluid as I could, then filled the reservoir several times while the fluid ran out, what came out was very cloudy and gritty, guessing the old box was chewing itself up.
Can't seem to find a straight answer - what fluid SHOULD this have in it?
Sounds like I should have used Mercon, looks like I grabbed Type F instead. Could that cause the steering effort to be extremely light? I mean like ridiculously light, tip of your pinkie barely touching and turning the wheel light?
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2004 F350 150,000km ... I have a rattling/clicking sound from the front right wheel when the hub is not locked (Free) and I hit small holes or run over rough roads. the sound is gone when I lock the hub front hubs.
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I have a 2001 f250 7.3 4x4 today I locked the hubs, put it in 4 low and got threw some mud to go hunting fine. got back out of the woods and took it out of 4x4 unlocked hubs and went in reverse 30 yards.. Now when i drive it makes a weird sound like a rubbing sound near the front axle. What this is?
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I have 2009 F-450 6.4L Diesel with 41K miles and just started to have a noise that can be heard up in the CAB of the truck while driving or idling. It sounds like a dry ball bearing that would go bad in home computer AC power supply or CPU cooling fan. The sound starts when the engine is at full operating temperature and most noticeable and the loudest if you are standing in front of the engine at idle outside.
Checked all fluids and they are normal. Turning the steering wheel doesn't affect the sound either or turning off the AC. Check engine light has not come on. The only thing I have noticed is that clutch fan stays on a very long time after starting cold and takes about a mile or two before it disengages. The truck is only used to tow a 36' 5th wheel and sits the majority of the time.
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