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2005 E-350, V10, Torqshift
Purchased new - about 70,000 miles now
It began as a slight pop (subdued metallic clunk) only when turning and only on the inside corner during the turn. A slow rolling turn wouldn't make the noise - there had to be some speed involved. Left turn = drivers clunk, right turn = passenger side clunk.
Took it to 3 Ford dealers - they were happy to take the $80 inspection fee and tell me they found nothing (one dealer replaced all ball joints, but it didn't help).
8,000 miles later the popping is much more consistent. It's louder now and happens on almost every turn. I even hear/feel it now sometimes on acceleration and or braking. It's louder and more consistent on the drivers side, but it does happen on both. Sometimes it seems like it pops one way then with a slighter pop settles back?
I see/find nothing that looks loose under the van - no telltale rust from moving surfaces and nothing looks out of place or worn. I did put a wrench on the radius arm nuts and they're snug. I pulled a the drivers set of wheel bearings and they looked good; snugged a spindle nut to 30#/ft for a quick test run and it still made the noise.
I have the Ford 100,000 mile extended service plan (=$100/visit), so I'm going to take it in again, and the noise is loud enough and consistent enough that they should be able to find it, but I'd like to be able to offer the Service Writer some suggestions.
Can anyone help with any suggestions? I posted on another board, but exhausted their ideas. Let me know if a picture of somewhere on the underside of the van would help...it wouldn't be a problem.
Purchased new - about 70,000 miles now
It began as a slight pop (subdued metallic clunk) only when turning and only on the inside corner during the turn. A slow rolling turn wouldn't make the noise - there had to be some speed involved. Left turn = drivers clunk, right turn = passenger side clunk.
Took it to 3 Ford dealers - they were happy to take the $80 inspection fee and tell me they found nothing (one dealer replaced all ball joints, but it didn't help).
8,000 miles later the popping is much more consistent. It's louder now and happens on almost every turn. I even hear/feel it now sometimes on acceleration and or braking. It's louder and more consistent on the drivers side, but it does happen on both. Sometimes it seems like it pops one way then with a slighter pop settles back?
I see/find nothing that looks loose under the van - no telltale rust from moving surfaces and nothing looks out of place or worn. I did put a wrench on the radius arm nuts and they're snug. I pulled a the drivers set of wheel bearings and they looked good; snugged a spindle nut to 30#/ft for a quick test run and it still made the noise.
I have the Ford 100,000 mile extended service plan (=$100/visit), so I'm going to take it in again, and the noise is loud enough and consistent enough that they should be able to find it, but I'd like to be able to offer the Service Writer some suggestions.
Can anyone help with any suggestions? I posted on another board, but exhausted their ideas. Let me know if a picture of somewhere on the underside of the van would help...it wouldn't be a problem.