Front End Clunking Over Bumps

[nsindel]

Hello Peter -

Thank you for the message.

Unfortunately, no there is nothing loose like a heat shield or the PTU cooling hardware (I don't have that).

It's over all bumps and uneven road. Can feel it in floorboard and pedals, and nobody can seem to help with this. I've spent a considerable amount of money on this.

I know the upper hydraulic engine mount is leaking a bit, but thats the opposite side of the engine compartment. Don't know if it could be a different mount, but my mechanic has taken a prybar to everything...

Ford dealer has given up on it, and I grow concerned that this will lead to catastrophic failure sooner or later.

Bummer, I really like this vehicle.

 

[IceSlade1]

I had a similar issue on my 2016. Replaced everything you guys all did. Noise was still there. Then I fugured out it was the engine mounts. Best bet is to replace all 3. Both sides and then the dog bone underneath. This definitely made my clunking noise go away.

 

[mwarney52]

2015 Ford Explorer XLT 3.5L V6, Everything stock.
I'm the third owner and bought this from an owner who lived on county gravel roads so I know it got plenty of washboard and rough roads in it's first 100k.

I get a pretty decent clunk that sounds like maybe the front right side when I hit any minor potholes. Distinct clunk with rebound clunk a couple times. I read forums and confirmed my suspicion of likely sway bar noise, maybe tie rod, or sway bar links.
Since I want a stable front end for wife and kids I just swapped out inner and outer tie rods, sway bar links, sway bar bushings...still getting the clunk. All parts replaced showed wear enough that it was a good call to replace for regular service. Also had a twang when steering hard back and forth so I replaced both front strut assemblies. That solved the twang sounds, but still have the clunking when hitting any pot hole.

Zero play in the wheel when I check wheel bearings and ball joints (done this a few times because I want to blame ball joints). Read some more and decided engine mount is suspect, so I changed the front right engine mount tonight...still getting the clunk.

I'm running out of ideas on the cause here. I removed that transmission cooling intake doohickey underneath just to see if that possible was the cause, but the clunk is deep enough it sounds very much like a suspension issue. The fact if I rock the car even fairly slowly (10mph) through a pot hole I get this 3 or 4 clunks back, I keep thinking suspension. I took a hard look at the lower control arms with their rubber bushings and can't see anything suspect, and cant get any play on them when I mess with em.

At this point I feel the only things left are the second motor (transmission mount), control arm bushings, or ball joints that are currently passing my checks.

What am I missing on this damn clunking?

Hade a "clunk" coming from front end of my 2013 Explorer. I turned out to be loose/worn stabilizer bars.

 

[nsindel]

I had a similar issue on my 2016. Replaced everything you guys all did. Noise was still there. Then I fugured out it was the engine mounts. Best bet is to replace all 3. Both sides and then the dog bone underneath. This definitely made my clunking noise go away.

Good morning IceSlade -

Thank you for your post. I was debating whether or not to chase this issue with these mounts, thinking I would be throwing good money after bad, but your post helped make that decision...

Question: did you use Ford parts or did you go aftermarket? there is, of course, a significant difference in price.

UPDATE: I checked and Ford has an updated dogbone - the package deals from aftermarket still uses the old design. Ford parts ordered.

Thank you

(thank you as well mwarney - I've changed those two times now, with no results. I appreciate the post.)

Nathan

 

[peterk9]

I had a similar issue on my 2016. Replaced everything you guys all did. Noise was still there. Then I fugured out it was the engine mounts. Best bet is to replace all 3. Both sides and then the dog bone underneath. This definitely made my clunking noise go away.

Welcome to the Forum.

Peter

 

[nsindel]

and good morning -

Replaced all three mounts

Thanks to Going to Replace Engine/Trans/Torque Mounts
(about 4 hours with hand tools, but that dogbone is a BEAR to get in)

and that didn't solve the problem.

Bummed. 2 trips to dealership, 2 independent mechanics, and still with this.

Oh well, I was hoping to have a better report. Thank you all for your input.

Nathan

 

[nsindel]

Good afternoon Explorer Forum:

Updates on this, and finally we have some good news... and a word of caution.

After replacing three strut bearings and always ending up with noise in a matter of days/weeks, my mechanic recommended that I purchase a loaded assembly as he was out of ideas, so I did:

Monroe Strut & Coil Spring Assembly

funny thing, as I looked the part up, I found (the attached) Monroe installation instructions, and I think we found the issue...

YOU NEED TO PUT THE CAR ON THE GROUND BEFORE YOU TIGHTEN THE UPPER NUTS. My mechanic had been tightening them while the car was still on the lift. This prematurely (as in within weeks) kept killing the upper mount. Not sure if this should be tribal knowledge for a mechanic, or if our vehicles are particular to the process, but its been 4 days now and no noise.

I will update this thread if the noise comes back, but if there is no update then the problem is solved

Nathan

 

[dpaul]

Old thread but thought I'd throw my experience in the mix anyway.

2014 Explorer, currently 120K miles. Started hearing the front end clunking over bumps about 5K miles ago. Very similar to what @Mtredneck described as " Distinct clunk with rebound clunk a couple times".

I could see that the LCA bushing were worn so I replaced both LCAs with Mevotech CTXMS40185/6, not the best but not the cheapest. No change in the noise. Then replaced the struts with Monroe 272729/30 because they were old, the rubber boots were destroyed and some corrosion was evident. Getting the strut off required cutting the link bolts on both sides so the links got replaced with cheapo Advance auto Carquest parts. If anything, the noise got worse.

Finally, I followed the suggestion of @Odrapnew above to undo the links and tie up the swaybar for a test ride. NO NOISE. I could have done this first and saved a lot of agony. So I replaced the bushings with Autozone $22 cheapies and the problem was solved. I'd spent $600 and 6 hours of labor on parts I did not need but at least I'm done for now.

 

[Bobs2018ExplorerSport]

While I wasn't dealing with any kind of "clunking" or noise issues, per se, I also decided to replace my OEM front struts (at about 87K) with the same Monroe Quick Struts (272727/30), thinking that perhaps the amount of mileage had probably made the front struts a little mushy. I also replaced the original sway bar links on each side (that attach to the struts) with new OEM Ford links (as I didn't like the "cheap" look of the Moog units being offered). It just made sense to me to change those out as well, since I'd have to disconnect the old links anyway.

Well, it took me about a day's worth of 1-man DIY labor to perform the swap (plus a minor realignment at a local shop when done), but man, was I pleasantly surprised at the change in handling performance! I can definitely feel the increased firmness in the front end, and better control on our sweeping off-ramp turns at speed, as well as less bouncing on some of our local "roller-coaster" road surfaces!

What I liked about the Quick Struts was that you were not only replacing the "shock absorber" unit, but also getting a new spring and a new rotating bearing surface mount, all at the same time... without having to worry about the dangers of using spring compressors, either!

And, yes, I had to put the vehicle on the ground, if for nothing else than to just to get the threaded studs on the top to protrude out through the body mounting holes enough to get the nuts threaded on them.

The Monroes were definitely a very reasonable investment (sold on Amazon) for a huge difference in handling results!

 

[bigmark5275]

Mine ended up being both lower control arm bushings.. replaced both control arms and quiet as a church mouse

I replaced the whole assembly and still getting same exact sound

 

[bigmark5275]

I would bet you $100 it's the front lower control arms. Replace both! People will look at them and they "appear" fine. It sucks to pay the $ on a chance, but I went through it on two Explorers. I can almost assure you that's the issue. Find a good independent and replace with OEM parts. Do NOT use MOOG unless you want to do it again in a year.

Shumax

Well I'd take that 100$ because replaced both of mine with OEM parts and still getting same exact sound.

 

[peterk9]

I replaced the whole assembly and still getting same exact sound

Welcome to the Forum.
Instead of throwing parts at it, why not have the dealer look at it?

Peter

 

[texsn95]

I replaced the whole assembly and still getting same exact sound

Did you replace your sway bar bushings as mentioned in post 28?