Ideas
Ive fixed the final amount of noise in the front end...
replaced all four tie rods
Still have clunking I think its in the brakes
ive got something similar going on. I just had an alignment and they said my ball joint and tie rod ends were good other wise it wouldnt hold the alignment. i cant wiggle the front driveshaft, nor the cvd's. i tried the tie rods but they dont move either. i cant visibly see anything wrong with the sway bar end links either. i'm going to recheck all the bolts for the breaks. it happens over rough construction, and ive felt/heard it when i'm braking, just not in the pedal. occasionally in the wheel maybe.
i can feel my thunk in the floor under my feet most of the time, maybe the transmission mount?
Have you tried lubing the slip yokes in both the front and rear driveshafts? Also check for "slop" in the pinions, and at the t-case input and output shafts.
I have another thought; something nobody seems to talk about much: Check the 3 rubber mount bushings that attach your front differential to the chassis. Get a heay pry bar on the diff, and put some torque on it, in different directions. See if the bushings/diff moves. Mine were worn out. They are definitely dealer only. The one on the driver side is sold as a complete bracket w/bushing (#1), the other two are the same, just a rubber bushing (looks like a control arm bushing). One is on the end of the passenger side axle tube (#2) and the other is on the top of the "pumpkin", on the passenger side (#3). I also found that the bolt holes on my chassis, for the #2 bushing were worn slightly oblong, possibly allowing additonal "slop". I ended up welding a heavy duty washer of the correct size on the rear side of the rear hole for reinforcement, and to eliminate slop.
The ford part#'s (as of 3/13/2008) were:
#1(bushing/bracket combo) 3L5Z3K090AA List Price $160.93
#2 & #3 (bushings) F67Z3A443AA List Price $28.75 each
I would recommend reusing the original NUTS, as they have integral "tabs" on them to prevent them from spinning as you loosen/tighten them. This allows you not have a 2nd wrench or ratchet on the nut (very difficult on at least one of them). I replaced my bolts with grade 8 stuff from a good hardware store. ( You won't find what you need at Home Depot). Don't forget to use lock-tight.
Also, FYI, while you're there CHECK YOUR MOTOR MOUNTS! They'll never be easier to get to, as you will have the front driveshaft, entire front diff,and both front cv axles removed (did I forget to mention that?
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