Mystery front end problem

[MMcConnell]

I've got 72,000 miles on my 06 CTD. For the last 5,000 miles or so, I've been experiencing a vibration originating from what I suspect is the front end. I feel it mostly while driving at slow speeds and over bumps or uneven surfaces. I can feel it in the steering wheel, as well as the brake pedal. Most recently, I am experiencing a popping or clunking from the front end, again under the same circumstances. I have spent hours researching these symptoms on TDR as well as other forums, but I have yet to figure out where the vibration/sound is coming from. Thus far, I have installed new bushings in the track bar, installed new sway bar links, installed a red head steering box along with a borgeson steering shaft, installed a BD steering brace and Bilstein 5100 series shocks. I have also checked the control arms and they appear to be tight. Today I took it to the dealer and they checked the bearings, ball joints, and axle u-joints and they all checked out ok. I am out of ideas and this clunk/vibration is driving me nuts. Any ideas of what could be causing these symptoms, or any ideas of what else I can check? It's frustrating to pay the amount of money that these trucks cost and experience problems like this. This is the second 3rd Gen. CTD I have owned, but I am seriously considering switching to a GM. Any info. is appreciated, thanks in advance!

 

[bigblock_doc]

Last Sept. put in upper and lower ball joints, hub bearings, axle u-joints. The ball joints

were making a clunking noise over small cracks or holes. Noise was gone untill two weeks ago. Clunking came back. Thinking it was the Moog ball joints going bad, it was the sway bar bushings. You could see daylight around the bar through the bushing.

New bushings, no more clunk.

 

[MMcConnell]

Now that is something I have not checked. I will check them the first chance I get. Where did you get replacement bushings from?

 

[AEdelheit]

I would also have someone turn the wheel back and forth lock to lock while you watch the front end, you will be surprised how much movement there is and it can make problems easier to find

 

[JFought]

track bar bushings can clunk. i replaced the track bar bushings, (lukes links) and soon noticed a clunk, i checked the bolts, i had it really damn tight, couldn't get any tighter.
I put my air impact on it for about 30 sec's couldn't see it move
But guess what!!
Clunk all gone!!

 

[MMcConnell]

Checked sway bar bushings this evening, and they appear to be ok. I had my wife turn the wheel lock to lock while I looked under the truck, and I couldn't see anything that appeared to be loose. I don't experience the clunk/vibration through the steering wheel and brake pedal if the truck is sitting still. It is only when I am moving, usually at slow speed. The track bar bushings were my first suspect when I first started having this problem. I replaced them with Lukes Links, tightened the the bolts with an air impact, then used a three foot breaker bar and torqued them as tight as I could get them. I couldn't tell any difference before/after I did the trackbar bushings. I don't know what is loose, but it's driving me nuts!

 

[TCDiesel]

Transmission cross over bolts are lose. You ready need a good impact to get them tight. .

 

[MMcConnell]

Transmission cross over bolts are lose. You ready need a good impact to get them tight. .

Are you referring to the the bolts that attach the transmission to the cross member?

 

[Wingate]

OK. . while some may not believe me... I have had this issue with my 06 model on 3 different occasions... and EVERY time it has been something different. . (and some really strange)

The first time, it was actually the overflow tank... the coolant was sloshing just right when going up my gravel driveway at low speeds...

I added a little fluid to change the level and presto. . no more noise. .

The second time about 6 months later was the insulation along the firewall had fallen off and was clunking against the firewall. Got some REAL aluminum rivets and fender washers and fixed THAT. .

Third time about 8-9 months later was a POS disposable cartridge type unitized hub bearing assembly... . THAT one I could feel in the steering wheel, brake pedal, and hear. . Truck was under warranty at the time, dealer tried to say it was within spec, I forced the issue and they replaced it. Noise went away... hasn't returned.

I will be doing away with those eventually and installing a free-spin kit...

Just some things to check...

 

[TCDiesel]

Are you referring to the the bolts that attach the transmission to the cross member?

The 4 Big one that attach the cross over bracket to the frame.

 

[TCDiesel]

Are you referring to the the bolts that attach the transmission to the cross member?

The 4 Big one that attach the cross over bracket to the frame.

 

[TCDiesel]

Are you referring to the the bolts that attach the transmission to the cross member?

The 4 Big one that attach the cross over bracket to the frame.

 

[MMcConnell]

Checked the transmission cross bolts, and they are tight as well. The longer I think about it, the more I believe it may be coming from the front shocks. The clunking never appeared until after I replaced the factory shocks with the Bilstein 5100's. When i removed the front shocks, the stock ones fit much more tighter in the lower mounts that the Bilsteins did. I torqued the bolts to the factory specs, and then a little more. First chance I get, I'm going to pull the front shocks and go for a short test drive and see if that solves the problem. Thanks everyone for the help. I'll post my findings.

 

[TCDiesel]

Those Cross bolts need 150 Ft Lbs, We need our 3/4 impact to get them tight... 1/2 will do it ,let crank good.

 

[Wingate]

Those Cross bolts need 150 Ft Lbs, We need our 3/4 impact to get them tight... 1/2 will do it ,let crank good.

Man. . you REALLY need to buy a new impact, or check your torque wrench calibration...



My 3/8 drive will run over 300 fl lbs all day long... 150 lbs really isnt that tight. .

 

[TCDiesel]

I here Ya... But most owners don't spend the coin. . for correct impact. . I guess I should rephrase 150 ft lbs MINIMUM. Every Impact we own will twist your arm off is you are not careful. . I see those China depot (CH) specials that are rated for 250 ft lbs ,you be lucky if you get 175 with that pancake compressor, and that on its best day...

 

[mroodzant]

my suspicion is Axle joints. I had similar symptoms, took it to shop, found out this is very common issue.

 

[TimothyLong]

Checked the transmission cross bolts, and they are tight as well. The longer I think about it, the more I believe it may be coming from the front shocks. The clunking never appeared until after I replaced the factory shocks with the Bilstein 5100's. When i removed the front shocks, the stock ones fit much more tighter in the lower mounts that the Bilsteins did. I torqued the bolts to the factory specs, and then a little more. First chance I get, I'm going to pull the front shocks and go for a short test drive and see if that solves the problem. Thanks everyone for the help. I'll post my findings.

Did you load some weight on the front shocks before you torqued them down? If you don't, the shock may not seat properly in that lower shackle and cause the clunk. The factory manual says to do this anyway. I had the same problem when I put my Bilsteins in after I installed a leveling kit. It was getting dark and I was tired so I took a short cut and it came back to haunt me. When the clunking started, I just loosened the bolts a little and then torqued them back down. Clunking went away.

 

[MMcConnell]

Did you load some weight on the front shocks before you torqued them down? If you don't, the shock may not seat properly in that lower shackle and cause the clunk. The factory manual says to do this anyway. I had the same problem when I put my Bilsteins in after I installed a leveling kit. It was getting dark and I was tired so I took a short cut and it came back to haunt me. When the clunking started, I just loosened the bolts a little and then torqued them back down. Clunking went away.

I plan to do this over the weekend. Thinking back, I believe when I installed the shocks I torqued the lower bolts without any weight on the shocks. Hopefully it will work for me too.

 

[MMcConnell]

Finally got around to checking the shock absorber lower mounting bolts today. I loosened each of them, then took a torque wrench and torqued the bolts to factory specs, then added a little more just to play it safe. Took the truck for a test drive, and clunk still there. Brought the truck back to the garage as I needed to change oil. While I was under truck draining the oil, I looked everything over. I placed my hand on the steering shaft where it attaches to the steering box and seen if there was any play. To my surprise, I noticed a small amount. By small, I'm saying a few thousands of an inch. The shaft on the steering box had no play in it, just where the connector slides over the gear box shaft. Just to experiment, I removed the Borgeson steering shaft, and installed the OEM which I still had laying around. Took the truck for a test drive, and to my surprise, no more clunk! The Borgeson had no play in the u-joints whatsoever, but apparently where the shaft connects to the steering box, it had enough wear or the tolerances were not tight enough to eliminate all movement. I put the Boregson on last Fall, the same time I put on the Bilsteins. I am surprised too that this was the culprit. Nonetheless, I am astatic that I found the problem and corrected it. Thanks everyone for the help!