Clicking/crunching noise from front end

[Mattbuyshouses]

First let me say hello all, it's been awhile since I've posted in this forum and I don't know where I'd be today without some of the assistance I've received here on multiple occasions... thanks everyone for being so helpful.

Now on to my new sitch with the sploder....

95 XLT 4x4

Had the brakes completely done last fall (about 6 months ago) rotors turned etc. While I was in there we also corrected a problem I was having with the ABS... replaced the hubs (some info here) http://www.explorerforum.com/forums/showthread.php?t=144250 which corrected the problem with the ABS always kicking in. While the front end was torn open I'm not sure why I didn't just flop the couple extra hundred down and fix the remaining problems I'll never know... I've had this clicking/grinding/crunching sound for sometime now. At low speeds while braking or slow cornering there is a thunk, thunk, thunk sound or loud click while turning left. Had the brakes checked recently to see if something there was causing it. No problems with the brakes, calipers or rotors. All brakes are in great condidtion. We inspected a small hole in the CV boot on the driver's side near the wheel and concluded that could potentially be the problem. Inspected the ball joints etc., and control arms for any play, no issues.

Here's what I'm faced with today. I'm going to throw down the following replacements on Tuesday and wanted to get anyone's feedback as to anything else to do while we're at it.

Half-shaft replacements (59.99 w/30 core) for remans. Both sides.
Lower ball joints (14.99) both sides.
Upper ball joint (69.99) driver side.
Upper ball joint (89.99) passenger side.
Front dif. outer seals (8.99) ea.
Front shocks (light duty) 15.99 ea.

Anything else to do while we're at it? The brakes are already done, the hubs are in great shape, rotors look near perfect... Time to replace the front shocks maybe?

Just wondering if anyone would suggest any other parts to change, fix, inspect, etc., while it's all opened up. We're planning on spending the time it takes to get the thing done so might as well get 'er done!

Thanks for any info!

Matt

 

[dreamghost]

I just had a my lower and upper ball joints done on the drivers side done on friday. Since then i kept hearing the same noises you do. Today my moms boyfriend took the front drivers side wheel off to take a look. And it appears the dusk plate/backing plate has rusted and one of the screws holding it in place fell off.

Those are good prices for the parts. They charged me $159 for the drivers side upper.

 

[Mattbuyshouses]

I should have stated that all the prices I quoted were for parts at Autozone (labor not included).

"dusk plate/backing plate"? Are you talking about the splash shield? Did you replace the missing bolt and put the shield back in place? Did the noise stop?

Matt

 

[dreamghost]

yeah i mean the splash shield. I have replaced the bolt and the noise went away. But the part is pretty rusty so im gonna have it replaced when i have my cam shims done.

That price was just the part price. Labor was $80 a hour x 3 HRs

 

[Mattbuyshouses]

I guess I'll consider myself lucky....

Just got back from the parts store a couple hours ago, dropped $395 (60 in cores) for the parts and the labor is going to be $200.

While it's being worked on I'm going to check the diff's fluid levels, inspect (and replace probably) the rear shocks and check and probably change the tranny fluid.

It's nice having a friend that has a couple of lifts and will do the work inexpensively. Plus it's not so bad getting all the extras out of the way too.

 

[Mattbuyshouses]

Clicking/clunking noise alleviated!

Here's the steps I took today.

Changed:
Both driver and passenger side half-shafts - $59.99ea
Both outer seals on front differential - $10.00ea
Front shocks - $15.99 (Guardian light duty)
Both lower ball joints - $14.99
Passenger side upper ball joint - $40.99
Filled to capacity Transfer Case lubricant (Mobil 1 Syn SAE 75W-140) - $15.99

Driver's side CV boot had a small hole about the size of Lincoln's head on a penny and while wrestling it into the core return box I noticed the joint was very rough. The ball joints were all inspected, driver's side upper was replace about a year ago and is in good shape, lowers on both sides were replaced today as was the passenger upper side. I got 2 different passenger upper joints from the parts store... one had the arm where the ball joint sits in the middle looking somewhat like a wishbone (exactly like the driver's side upper) and the other had the ball joint in the middle with two bolt holes, one at either end of each arm. The instructions in the box said that the old unit could be replaced by the new one (again, resembles the driver's side upper) but we opted to go with the original looking item. Not sure how one would adjust the alignment without it, so that's what we went for... plus, it was half the cost as well.

Tie rods, stablizers etc., were all inspected, hubs were inspected and greased, brakes re-inspected, all grease serts were filled, bushings lubed and so on. Long and short, while we were in there, if it could squeak we lubricated it. Since the whole front suspension was dismantled everything was accessible so we left no stone unturned.

The outer seals for the differential were a bit stubborn coming off and had to be "persuaded" with a prybar and tapping but eventually came free. The new seals went in fairly simply and seated well. These were the most difficult part of the process. Everything else was pretty straight forward.

Later this week we're going to do the rear shocks and check and fill the rear differential and inspect and possibly replace the rear stabilizer (5th shock) or stabilizing link.

I'm also going to check the u-joints for both front and rear driveshafts which were replaced with greased fit joints about 4 years ago. So far they haven't posed any problems but since I've got the money and the time currently, it's not a bad time to replace them.

 

[Mattbuyshouses]

Well crud,
I guess I spoke (wrote) too soon on the noise. Apparantly it's still there. I noticed it tonight a few times once when I was in the drive-thru at a fast food joint. It's amazing the accoustics when you're right next to the building like that, really made it easy to distinguish the sound again.

It certainly sounds like a cv going bad but since I've just replaced them a couple days ago probably not.

Most of you will be familiar with this... turning left around the corner of the building in the drive-thru creeping up to the window... click, click, click... a little creak or two as well (ball joints just replaced as well).

Guess maybe we need to look at the tie rods, stabilizers etc., maybe something there is worn out that we missed on Tuesday.

It'll be on the lift tomorrow so I'll update this when I get done at the shop.

 

[skoal_mint]

did you find out the problem yet, im intrested in this one, lol

 

[Mattbuyshouses]

Not yet, I'm still racking my brain on this and the shaking at highway speeds.

It's my thought that the clicking I'm hearing at "drive-thru" speeds is the driver's side caliper or shoes. The rotors were turned this fall and the brakes have been inspected since (visually only while doing other things) and look in great condition. Since these calipers have two pistons inside I'm wondering if maybe one of them isn't travelling all the way down under light braking conditions. Perhaps the lines needed to be bled? Don't know what the symptoms of air in the lines is, squishy brakes?

I'm putting new calipers on this Wednesday and also having new u-joints installed on the driveshafts. Hopefully the new calipers (and probably new pads) will clear up the slow-going clicking.

 

[skoal_mint]

lol, dod you have any rocks in your tire, my mom had take a look at her car because she thought somthing was failing, as i was walking be the car i saw a rock in the tire, lol

 

[Mattbuyshouses]

No rocks in the treads and just did a rotation but noise didn't change. Checked all around the tires first time I heard it... nothing stuck anywhere in the treads at all. Good idea otherwise tho... nothing like a quick (and free) fix!

 

[Mattbuyshouses]

Replaced the front brake calipers on Wednesday and the clicking at slow speeds is gone. From the wear on the back of the brake pads it looked like one of the pistons was sticking. In any case, the noise of click, click, click when going thru the drive through is now gone.

 

[Bowhunt24]

that was quite the process you went through...I don't even want to know what the total bill was after all those new parts!!!! I read through this thread because my '96 EB is doing something similar. Just had 4 new shocks put on, both front hub assemblies replaced, brakes done last year, but recently inspected, and checked out okay. Also, had the alignment and camber fixed all around as well, but still after all that, a little shaky at highway speeds, and a good hard wheel shake at medium speed corners...any ideas on what parts to attack next to help get my Expolder back to as close as factory ride quality as possible?? Take er easy

-Evan

 

[Mattbuyshouses]

Monday I'm taking it to a driveshaft specialist and having the front driveshaft u-joints replaced. The 95XLT front driveshaft has a CV joint at the rear of the shaft (two u-joints connected by a ball and socket) and takes a little more than a do-it-yourselfer bench vise and hammer to get it done. Also, they'll be checking both front and rear shafts for balance. From my description today to the "expert" his reply was that it was most likely the rear driveshaft causing the problem. Since I have already replaced the u-joints on the rear, this makes me wonder if it isn't out of balance. He'll be able to check that on Monday. The front u-joints are as old as the rears were (about 5 years) and are probably not in the greatest of shape since they were the kind with grease serts in them and hard to reach. I'm guessing that since I didn't grease them and even though I asked them to do it each time I got an oil change, most likely they hadn't been done in quite awhile and are probably failing now. Hopefully Monday will put an end to the unpleasant shaking going on at highway speed. I'll let you know.

Matt

 

[Bowhunt24]

yeah, sounds good, let me know if your driveshafts were out of balance. thats a good thing to check, I never thought of that.

-E