Clicking in Front end after Carli install?

[JCockerill]

Guys who have Carli suspensions up front,



I recently installed the starter kit, springs, shocks, sway bar end links, and an adjustable trackbar. as soon as i test drove the truck you could hear a light clicking allmost a cluck when you would hit hard bumps. So i re checked and tripple checked all components for tightness and correct install. I still get this noise that was never there prior to carli kit. I was starting to think it is the new heim joints in the track bar and sway bar links. since they are soild rather than rubber and i'm not use to it. it just doesn't sound right. the sound is allmost like a loose caliper. (I checked those too) otherwise the truck rides nice, and front end is untouched until i installed the kit.



If any of you with carli kits have any insight, I appreciate it!



thanks

 

[champspa]

did you check the ujoints in the front axles ?

 

[JCockerill]

yes, u joints are ok. the thing is, the nosie started after the install, so it's something that was changed. is it normal for the heim joints to make a bit of noise?

 

[Rams-n-Hogs]

Make sure the track bar isn't hitting any part of the frame on the drivers side. I just put one on and I had the same issue, although mine is a Thuren. I'm not sure if the Carli mounts the same way. I had to grind out part of the frame that hangs down to get it to stop.

 

[Regcabguy]

Should be silent. Give Carli a call when they open @ 9:00 am pst. Sounds like the trackbar might need another tug. The springs need to settle in,but that's usually a one time event.

 

[Bob4x4]

Make sure the steering shafts are not the culprit. It is a very common issue on the 06,even on stock trucks

 

[Mobius1]

Tighten up your track bar. I had the same issue even after track bar was installed with an impact gun, I still gave it another half turn, and noise went away

 

[JCockerill]

Make sure the steering shafts are not the culprit. It is a very common issue on the 06,even on stock trucks

Bob, when you say steering shafts, do you mean from steering wheel to box?



i will check tighness of track bar, and torque spec.



it's light a light rattle from front end over bumps.



Also, is the reference (rotation) of the front coils important? i have the carli lable facing out on one side and not the other.



thanks for the help guys

 

[Bob4x4]

Yes there are 2 shafts between the steering column and gear box,u-joints and a slip joint. They make a very light clunking on certain road surfaces(can be felt in the steering wheel) and as they get worse you will be able to reproduce it by applying the brakes at parking lot (slow) speeds. When it has progressed enough you can grab the shaft(s) from under the hood and feel extra motion.

 

[Tejasdge]

The bottom shock bolts are a common cause of popping and clunking as well.

 

[JCockerill]

WTF! after checking track bar and steering shaft for tightness (everything was tight) and just instaling a bilstein steering damper and caught my first case of death wabble at 75 mph in three lanes on traffic! allmost wrecked the truck! 52000 miles and this has never happend. after all the f**ckin money i have spent on parts to make a sub-standard truck driveable, this is what happens! is it the damper or what? btw the tires are stock. . they are allmost shot but still... I'm getting it aligned tomorrow then will see if this cures it, It seems the caster gets thrown off by 3 in front extension. plus the track and toe have to be off a bit. if not i will rip out the bilstein steering damper and put stocker back in.

 

[JCockerill]

Yes there are 2 shafts between the steering column and gear box,u-joints and a slip joint. They make a very light clunking on certain road surfaces(can be felt in the steering wheel) and as they get worse you will be able to reproduce it by applying the brakes at parking lot (slow) speeds. When it has progressed enough you can grab the shaft(s) from under the hood and feel extra motion.

what is the sugested replacement if the steering shaft is worn out?

 

[RMeans]

genos garage has a replacement shaft

 

[JCockerill]

Guys,



I have been over and over this front end. It has every part that could be replaced. I still get a clicking clunck sound every time one of the front wheels hits a medium size bump. I have gone over every bolt for tightness. I know steering shaft was mentioned, but is has no play, and i don't feel anything in wheel. I have added the following parts since noise started:



Carli starter suspension (springs and track bar), which was installed first and when noise started.

07 Steering tie rod update (t-style) with nem pitman arm

Carli sway bar and control arms.

Dynatrack free spins and ball joints

Steering box brace with replaced box from dealer.

bilstien 5100 shocks and steering stabilizer.

I also updated to newer style larger track bar bolts.

truck sits on 35" toyo m/t's



I just dont know what else to do. there is no play anywhere. shock bushings are tight, all bolts are tight. the noise is driving me nuts after spending this much time and money. Truck drives fine and feels tight just can't stand the loose sounding noise!



please post any feedback you might have no matter how basic it is.



thanks

 

[firemansdiesel]

I had simiar issue when I first installed my Lorenz Sysyem on my '05 CTD. After talking to Sean about the the noise going over uneven pavement. He suggested that one of my lower shock mount bolts was not in all the way and pinching on the shock bushing (front shocks). Sure enough my passenger lower bolt was not in all the way before tightening. Even though it seemed installed correctly the first time.

Just a suggestion since you went over every other issue that may have caused the sound. Especially if the sounds is coming from the front.

 

[SierraRam]

I would second the lower shock bolt. If they tightened the bolts while on the lift they will bind when sitting on the ground and pop when hitting bumps. Loosed the lower bolts while the truck is on the ground and then retighten.

 

[JCockerill]

interesting, let me try this. Thanks guys!

 

[JCockerill]

ok,



loosened up bottom shock bolts on ground, they where tight as hell, and when i did tighten them upon original install suspension was at full droop on lift. I left the bolts a few turns loose and drove around block. Noise now was worse and confirmed the sound is coming from bottom shock bolts. I then retighten with 1/2 in breaker bar and test drove. noise is back to same it was before. still making racket over medium bumps. What gives? are the bilsteins bad? could the gromets be bad? i'm sick of it.

 

[TCDiesel]

Check transmission cross member bolts. . 4 big one's they need to be at least TQ to 250 FT lbs

 

[firemansdiesel]

ok,



loosened up bottom shock bolts on ground, they where tight as hell, and when i did tighten them upon original install suspension was at full droop on lift. I left the bolts a few turns loose and drove around block. Noise now was worse and confirmed the sound is coming from bottom shock bolts. I then retighten with 1/2 in breaker bar and test drove. noise is back to same it was before. still making racket over medium bumps. What gives? are the bilsteins bad? could the gromets be bad? i'm sick of it.

Hmmm, well it may be a bad shock bushing then. If you have not already called Carli yet, I would give them a jingle and tell them your issue. Sage and Shaun will tackle the problem. Top notch people!