Something is wrong with my axle knuckles...

[Palmer7]

Been getting a lot of popping noises from the front end recently and I just replaced my ball joints and tie rod ends. This is what I found.

Axle hits knuckle here on both sides.

And here both sides.

Kinda hard to see on the second photo but that's the back of the axle on my pass side and it hits in the top right in the picture and where it rotates on the ball joint retainer or hate we you would call it. Is there any specific cause for this?

 

[Albino 94LTD]

Is it popping when you step on the brakes or go over bumps in a straight line or is it only when turned to locked position?

 

[Palmer7]

Rarely over bumps and mostly when turning haven't really noticed it when braking.

 

[x-dog83]

1. When was the last time you had an alignment?
It seems to me that if your toe in was set too far in or out (can't tell from the photos or description) that you may be hitting your steering knuckles on your axles.
2. ALSO- when you replaced your ball joints and tie rod ends did you replace all appropriate bushings and washers?
3. Are your tie rods the right size?
4. (Help me out here), is there a mechanism in the steering that limits or SETS the amount of turn-till-wheel-lock?
There seems to be a lot of variables but I would love to know just as well as you would.
Any input would be appreciated.

 

[Palmer7]

1: my last allignment was right after I did my ball joints and tie rod ends so within a month.

2: I didn't change any bushing or washer I cleaned and re-greased everything though. What bushing/washers would have need to be replaced? Everything looked in good order.

3: I have stock tie rods so I would assume they are the correct size.

4: I'm not sure what you mean by this question please elaborate.

Everything is in good order that I can see it just seems that something like the allignment could be off but I couldn't see why a shop would screw up an allignment.

 

[Albino 94LTD]

I'll take a closer look at mine today.

It's not uncommon for the knuckle to hit the beam at full lock. There is a spot on the forging that acts like a limit pad.

By chance have you loosened the Radius arm/Beam bolts recently, like to pull the pumpkin?

Is it worse when in 4wd?

 

[x-dog83]

Out of curiosity i looked at mine today. I've got the same thing going on my 91sport- there's no play in the wheels and it only happens once in a while (durring sharp turns) i don't forsee a problem so far. I do a weekly check on my suspension and everything else is fine..

 

[Palmer7]

No I haven't done anything to the radius arm or beam.

I used the 4x4 over in Gearhart in seaside about 2 weeks ago and it didn't seem any worse.

It just seems weird because I have never noticed this before and I think it might have ha something to do with my ditch accident up a browns. (registry has pics of the damage)