Front Suspension and Steering Questions

snicklas

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First off, this is for my 03 Ex, but the Basement gets more traffic, and is a more general question.......

OK, the Truck: 2003 Excursion 4x4 6.0, D50 3.73 Monobeam Front axle (Similar to the D60's on the earlier trucks), Sterling 10.50 3.73LS Full Float Rear Axle.

My questions:

1st. The Track Bar. It mounts to the frame with a long "dog-bone" mount with bushings, I can see these bushings are worn and need to be replaced. I can, while lying under the side of the truck, and move the track side-to-side in the mounts in the front axle at least 1 inch, maybe more side to side. There is also some up and down play at the bushings in the dog-bones, but as stated, they are worn and will clunk in the right conditions.....

2nd, Drag Link/Tie Rod. I believe this is a similar setup to the D60, I have a "tie rod end" at the pitman arm, this end is attached to the drag link that goes toward the passenger side knuckle. About 3-4 inches before the knuckle, is another joint, this is a non adjustable, and appears to be non removeable joint. The tie rod then connects to the passenger side knuckle with a non adjustable end, and the tie rod connects to the drivers side knuckle with a tie rod end with an adjustment sleave.

Earlier in the year I hit a chuck-hole, the one that broke the drivers front shock. Shortly after I hit the hole, a pop/clunk developed in the front when the passenger side suspension cycles. I did another visual inspection and found the following last evening. Keep in mind this truck has ~110,000 miles on it, and all the front parts are original, except the ball joints, brakes and shocks. The shocks were replaced with Bilsteins earlier this year.

The steering stabilizer shock is shot, has not been replaced, has a bit of play in it. If I grab the drag link and roll the bar forward and back, it will rotate on the joint at the pitman arm and the tie rod, the drag link will clunk in one direction, as if it is hitting the tie rod. All the joints appear to be tight, and when the truck is sitting on the ground and the steering wheel is turned, everything moves as it should. While driving the truck, the steering is tight, it does not wonder, no death wobble, no bump steer. It is still aligned, I can remove my hands from the wheel at any speed and it continues straight downt the road. I am trying to get any ideas what it may be.... this is my family vehicle and do not want anything that can cause any problems to go unattended......
 
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mattplumber

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I really dont understand what the question is? Whats causing the "clunk"? You obviously have worn/busted parts that you've found: track bar, steering shock, and one front shock( didn't indicate if it got replaced when you hit the pot hole, so i'm assuming its still broken).

Replace the track bar/bushings, pony up for a heavier duty steering shock(monroe-moog-gabriel-KYB) they all make 'em, and replace the front shock thats broken and see if the clunk goes away.

Having owned a superduty, and worked out of several more, they eat front steering and suspension components just like their older brothers. A super duty/excursion is one heavy mother humper................

Also, have you checked your front unit bearings? They like to break and clunk and do funny things when they are about to go. And they especially dont fare well after hard impacts, i.e. pot holes. I've ruined more than my share- ask me how i know.............
 

snicklas

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Matt,

I am really looking for suggestions of what to look at, and what I have seen.

I have replaced the shocks, truck got a full set of Bilstein 4600 after the hit.

The track bar bushings have made noise since I got the truck. The sound I am hearing is not the same as I expect. (I know I should have replaced them before now.) Unless the hit made them worse.

The Track Bar Bushings and the Steering Stabilizer are the only things I can see, and I am having trouble wrapping my head around one of those two making this noise. I agree I need to replace these to eliminate the posibility they are the noise maker.

I do not think it is the unit bearing. The hubs are tight, no movement in the tire/wheel/hub that would indicate bearings. Also, the noise I am hearing is from the passenger side, and the wheel that hit the hole was the drivers side, so the side that hit the hole, and had the broken shock is not the side I am hearing the noise from now.

How hard are track bar bushings to replace? Do you replace the entire "dog bone" or just the contained bushings?

Could I temporarly remove the "dog bones" and take it for a slow ride around the block and see if the noise is gone, or is that not a good idea?

Thanks for the suggestions.... I am just not seeing anything obvious and trying to get a fresh perspective.
 

Diesel_brad

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agreed with DOUBLE. change your track bar bushings. there should be ZERO play in them. Maybe know they are worn far enough, it tis making something else clunk. Even if not they need replacing anyway
 

snicklas

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snicklas

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OK..dragging this back out of the dungeon.....

Due to the starter taking an unplanned vacation on my DD Sable Wagon, I am back to DD'ing the truck till payday. So I am remiinded this repair needs to be completed on the truck also. I did confirm it is the track bar bushings that are making the noise, not a broken component (spring, shackel, U-Bolt) that could be a safety issue. The front end is not going to fall off the trcuk, it is just an annoying noise (more or less)

Looking at the link that Nick posted, is that for a single bushing, for just one end of the link, or is that a set. It does not list it, so I am looking for the quantity to buy. I know that I can buy and entire track-bar link from "the zone" for $70 a side..... but there is nothing wrong with the link itself, just the bushing. Is there a trick to remove the bushing? A punch and a BFH, or do I need a press. If I need a press, the complete link looks like a better option for me.

I should also do the rear track bar bushings, I figure if the front are bad, then the rear are worn also. I just want to fix it correctly, so that I don;t have to worry about it for a few more years......

Also, just to make sure we are all on the same page, and that I am asking for the correct part. This link is what I am needing the bushings for. Sway Bar, Track Bar.... I have heard them called the same thing. I just want to get the correct part the first time.
 
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snicklas

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Thanks Brad,

Since I have no access to a press, maybe it would be better, in my case to pay a bit extra and get the complete link. They do have a lifetime warranty, at least when they fail again, they won't cost me anything but a little time to replace.

One other quick question, since I haven't worked on this type of part before, is there any weight/pressure/etc on the track bar links. If I have it on ramps, or sitting on the ground and slide under, when I disconnect them, will they be in a bind, or move and I have to move them back into place? Or do I need to jack the truck up, support the frame and let the suspension "relax" before I remove the links? I just do not want a surprise when I pull the bolts out of the link......
 

Diesel_brad

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It should not move hardly at all. It hay move but bot much. The only time I have ever had them out was when lifting a truck. And when it was time to reinstall it I had to use a ratchet strap to line it back up. But being you are not lifting of lowering, it should be a simple swap
 

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