2nd Gen Non-Engine/Transmission Front End Woes

[BenSeymour]

HI all, new here to the forums, and have searched the system to find some information on the 4x4 front end problems of these trucks. I have been fighting this battle for the last 3 years, much like everyone else on this forum. Now I have a problem that I find is somewhat unique. Maybe someone here can offer some insight. I have replaced the control arm bushings with poly ones, have all new tie rods/ends, DT Tracbar, which just got a new heim and poly bushing, has a DSS, just installed a new AGR gearbox (that's a whole other story/post :{ ). Now I have a clunk/pop that I feel/ hear through the steering column. Happens when I hit the brakes, and take off sometimes, and more recently, when coming around a corner fast, I feel it too. I haven't replaced the intermediate shaft yet, but it sure didn't feel worn (shook it up and down). Recently also had a trusted mechanic look over the whole front end including the ball joints (checked out o. k. with no play), and he said he couldn't find ANYTHING wrong with it. He's stumped too. I am about ready to lose my mind with this thing. On other thing- WHen I first start the truck up in the morning (cold) there are NO noises at all for the first 5-6 miles of driving, but the longer I drive it, the worse the noise gets, and the more you feel it. Anyone out there had anything similar to this? Any help is appreciated, and these forums are GREAT!

 

[rkressg]

Put it in 4wd and make a slow tight turn in a parking lot. Do this with the wheel at full stop in both directions. See if you can get it to clunk. If so, I would suggest checking the U-Joints in the front axle (behind the spindle). I have seen them go bad and cause a symptom like that.



Also, throughly check the sway bar links, bushings, and the bar its self. If they break, chances are, it will break behind the bushing where you can not see. Also, they will crack and not break fully for a long time, causing a clunk, but with no visable broken parts.



There could be something loose in the front differental also, but I would check these things out first.

-Rich

 

[AMink]

Welcome aboard! Have you checked to make sure that your shocks and shock towers are tight? Sometimes that gives the thump through the wheel. That's a cheap place to start looking. Also, if your shocks are older, the bushings could be shot. Good luck!

 

[jkeyes]

this sounds exactly like the problem that I am having. I am down to either a steering collum or an intermediate shaft. I do hope it is not the collum though.



Jason

 

[BenSeymour]

I don't think it's anything in the 4x4 arena. The noise is only on braking or coming around corners. i have a new intermediate shaft, that I will try to install when I am feeling better (dirtbike accident :-laf ). But after I drove it the other day and it got warm, I got out and shoved on the side of the truck and could hear a clunk on the outside. Had someone else do ti and it turned out to be the DT Trac Bar heim end (which is brand new). I can feel the ball moving inside the joint itself. Gotta call DT this week and see what they have to say. I don't remember it being this bad when I bought the original bar. Anyone else have the problem with DT bar out there? The shock towers are tight and are the lower bolts. Haven't replaced the sway bar bushings yet, but may do that just for the heck of it. I am so sick of this truck. I don't even like driving it anymore, it just feels like it is coming apart underneath me. Oh well, enough of my complaining. Guess I will just have to wait until I can afford to rip out he front axle altogether and replace it with something that works. Thanks guys, take it easy-

 

[Dane]

Anyone else have the problem with DT bar out there

Yes, but the problem was my fault



I had the clunk you describe exactly. My problem was not the heim joint, but the other end of the DT track bar. I have a habit of using lots of penetrating oil and then protectant oil when I remove/install parts on all my cars/trucks. I think the habbit was started by restoring old cars, which is my hobby.



Anyway, when I installed the DT trackbar I used too much Valvolene synthetic grease in the plastic bushing and caused the bolt and nut to not be able to hold the bar in place. The bar was shifting side to side. You can see the shift when it clunks. I cleaned the bar end, frame, bolt and nut with brake clean - No more clunk! Oo.



I did find the hole that the bolt goes through had enlarged itself a bit, but since cleaning and retorquing, the track bar does not shift anymore.



Also, I did install a new bushing and heim from DT thinking the track bar needed rebuilding, but the clunk persisted. The blame lies in the mount, not the DT tracbar. I could have left the old bushing and heim joint in place.

 

[BenSeymour]

Called DT today about the Trac-Bar. Seem to be good guys to deal with. They are sending me out another heim and bolt/ spacers, etc. When I went to change the old one out, the bolt had seized itself inside the heim so bad that no amount of banging or torching would budge it, finally had to cut it out with a sawzall. After that, I had to replace the fine thread 5/8" bolt with a coarse thread from TSC. The guy from DT said that could be part of the clunk problem, (as I can actually feel the joint moving or maybe the bolt), but also said that it could possibly be a bad heim, as they are injection molded with polyethylene (something went wrong with manufacturing process). The other end of the bar is tight and I can see no movement. I think they make a good product, especially if your truck is lifted, but it's getting to the point that maybe the Solid Steel bar would be a better alternative. Anyone out there got one of those installed? Any other comments let me know. Thanks-

 

[emmettcrocker]

I had a very simular problem after replacing ball joints u joints and tie rod ends I discovered it was the lower shock mount bolts loose/worn. The stock bolts on my 99 3500 only have about 1/2" to 3/4" shank which leaves about 1" of the threaded portion in bearing with the shock sleeve allowing a very sloppy fit. Check it if you haven't already.

 

[TTroutman]

Same probem with 2WD 3500 '97

7k miles on following setup - AGR SB2 - DSS - Borgeson shaft - Saf-t-steer stabilizer - New Rancho Shocks - New Most Everything in Front End.



I think it's coming from the AGR, it seems to have slopped up really fast.

 

[jkeyes]

what is the AGR?

 

[TTroutman]

http://www.agrperformance.com/



Steering box by AGR.

 

[BenSeymour]

I finally got it Oo. ! Finally chased those "noise Gremlins" out of the front end of the truck. Well, for the most part. The steering wheel still has a little play in it (approx 2 in. of side to side movement), but after what I went through with this truck, it's fine with me. I replaced the intermediate shaft first, which seemed to take care of the majority of the noise (which I don't completely understand, because when I had the old one sitting next to the new one, and wrenched on them a bit, I couldn't tell any difference in the amount of slop in them, but I guess it must have been there, After that, I welded the DT bracket to the frame in a couple small spots (so I could cut it off later when I junk the whole front axle), and installed the new bolt/ spacers/ heim. Put it all back together, and drove it for about 2 hours yesterday, and not one clunk! Finally I like driving my truck again. Now if I can just get the the fried clutch out in favor of a new Con O, I think it'll be time to throw the bigger turbo and injectors on it