Dropping the truck off to one of 3 Ford stealerships here in ABQ tomorrow. I figured I'd ask on here for some input on what some of you more experienced/edjoomacated might think.
So here goes...
Before I was lifted, just running 33s I had an ever so slight clunk that was VERY infrequent. Upon lifting with the RCD kit, this went away for some time (can't think of how long exactly). It returned and I just lived with it since I couldn't get Ford in Las Cruces to duplicate it. The clunk appears to be in the front, driver's side. It happens when having been parked, starting up, and then turning left. I also get it at times when coming to a stop, particularly when parking in the garage. As of recently (last 2-3 weeks) it has gotten worse/more frequent with me hearing it at times while merely driving and hitting bumps.
As some have followed, I've done pretty much a complete R&R of my front suspension due to the awesome (no not really) bilstein coilover shocks and my passenger one failing back in July.
I have replaced the following on the front suspension, all within 1500 miles, possibly even 1000 miles, or less:
- DS & PS outer tierods (MOOG)
- DS & PS upper control arms (MOOG)
- DS & PS lower ball joints (MOOG)
- DS & PS inner tierods (MOOG)
- DS & PS CV axles
- DS & PS FOX remote reservoir coilovers
- DS & PS hub assemblies
- PS caliper bracket & caliper...compliments of PS hub failing and seizing, causing rotor to eat into said items
I also have a cyclic (vibrates for 5-6 seconds, smooth for 2 seconds...approximately) vibration at 77 mph and above, but I too have a good hum (not sure if I'd call it a howl) from 15-40 mph. My bfg 33/10.5/15 muds are getting a little long in the tooth, but I don't think it is them. They are balanced and both tires and wheels appear to be in round via Discount Tire. I have greased my, now old, rear driveshaft but that did not rid the clunk. I've also recently installed the RCD 4° pinion shims. The greasing was last summer and done while I also replaced the u-joints on both the rear driveshaft and my superlift driveshaft. Hum and vibration are present with or without the front driveshaft installed. Both are also present with the pinion angle adjusted (I'm now within 2°). I also had my old OEM rear DS balanced, which slightly reduced the vibration. I then tried a rear DS from a junkyard, found a shaft with I think 15 or 20K miles on it. Vibration and hum present with it installed. Both front and rear shafts are properly installed per marks on the flanges...though initially I was told it didn't matter when installing the superlift shaft, but I did note its orientation with a paint pen after I installed it.
Currently my thoughts are front and rear gears going for hum/vibration, though when I changed my rear diff's gear oil earlier this year I saw no metal in the old oil). My drive side caliper, though bolts are tight, does move by hand. The passenger side does not. DS caliper assmebly is my 04 OEM coupled with a 2002 rotor for RCD fitment. Clunk thoughts are rack & pinion or a busted engine/tranmission mount.
Other fears are rear wheel bearings, pinion bearings, t-case flange (there appears to be some play).
And on top of this all, I'm jobless since May 30th.
So besides the, blow up your truck (which I owe a whopping $1400 on), trade it for a toyota, get a chevy (gf's father and grandfather there), or some other sarcastic comment....any heartfelt, genuine thoughts of what could be going on?
Oh, I can get more specific on dates and mileage if need be. I'm going off the top of my head here. Getting specific will require some digging though as I'm in the process of trying to get all my non-ford related repairs and maintenance work organized into a spreadsheet. Sometimes I hate being an organized biologist/perfectionist.