Popping noise in front end when turning or flexing?????

[Titojeep]

So I've been told that our trucks are prone to some rivet coming loose in the front end resulting in a popping noise from a cross member or something. The noise sounds like a ball joint, however just replaced those, along with the bushings and still have the same noise. Anyone with the same issue and or any photos of which one it is? I've cleaned and looked at every one but have had no luck. I assume when someone says it comes loose that they mean it's worn in the middle and not necessarily obviously visible on the button end which is clearly visible? I'd also like to know what you've done to repair yours? Drill out replace with a bolt? Weld the area ( assuming it's in a place that can be welded?). Thanks in advance for any input.
1993 F350 DRW CC 7.3 IDI

 

[79jasper]

Never heard that.
You did the track bar bushings too?

 

[riotwarrior]

So I've been told that our trucks are prone to some rivet coming loose in the front end resulting in a popping noise from a cross member or something. The noise sounds like a ball joint, however just replaced those, along with the bushings and still have the same noise. Anyone with the same issue and or any photos of which one it is? I've cleaned and looked at every one but have had no luck. I assume when someone says it comes loose that they mean it's worn in the middle and not necessarily obviously visible on the button end which is clearly visible? I'd also like to know what you've done to repair yours? Drill out replace with a bolt? Weld the area ( assuming it's in a place that can be welded?). Thanks in advance for any input.
1993 F350 DRW CC 7.3 IDI

First gotta ask 2 or 4 wd? Makes a big difference in responses...may consider adding that info and trans type into your signature BTW! Then we won't ask what it is

Sometimes as my steering cycles while on rough terrain, my tie rods actually cycle on the ball joint making a bad noise yet no matter how hard I pull push etc they feel fine, it's like it's over centering and back kind of like an oil can noise for the old quart tin cans would make sometimes...except louder and so forth.

Anyway need answer to first question....

 

[idi_econoline]

Have heard that on my beast, especially when frame does a diagonal flex.

But not lately. Front end was checked recently by my very capable tire & front-end shop; all good.

Will be interested to hear if someone has this one figured out.

 

[typ4]

my 4x4 did it till I welded the front cross member in, everywhere you can reach. my buddy worked at Carmenita ford when these trucks came out and that was fords recommended fix for the flexi frame. Mine has been quiet since. I posted pics way back when I did it but i bet they are long gone now.

Im also going to do it on the 2wd while the engine is out, way easy to do then.

 

['94IDITurbo7.3]

check the fender bolts and the hood hings bolts at the firewall. mine did the same thing and i tightened up my fender bolts and the noise went away.

there is a TSB out for this exact issue and it does mention the engine x-member rivets breaking.

 

['94IDITurbo7.3]

http://powerstrokearmy.com/forums/showthread.php?t=23519

 

[Titojeep]

Forgot to mention it's 2wd. Sorry about that. As for bolts on fenders I've done all of that. I tried going to the Tech service bulletin link listed above but I'm not a member so couldn't log in. I'll copy the number and do an internet search. Sounds like that's the info I was looking for. Just need a picture or better description in order to locate it. The pop is very distinct. Case in point, my driveway is a slight incline at the bottom. As soon as I turn in, "POP"!!! The when I proceed and straighten up, "POP" again as I'm straightening back up. I'll definitely check out the TSP, if not then I may do what type 4 did and weld the cross member. Just want to be sure on what to do since I know that from an Engineering perspective, a certain amount of flex is factored in. I'd hate to stiffen something on one side only to find out later that I caused something else to crack / break somewhere else.

 

[whiteboyslo]

Mine's been making a creaking/groaning noise in the types of situations you're describing. Started after I took it down a very rutted dirt road once (way too fast, in hindsight). Haven't been able to track it down yet, and trying to NOT throw parts at it.

Mike

 

[Titojeep]

UPDATE - So I searched the internet for the bulletin posted on the power stroke link above, and found the extensive description of the issue from Ford. Too much info to post, but if you google search for TSB 97-3-10 you'll find it. Now the daunting task of figuring out which one. I'll post my findings when complete.

 

[Mulochico]

Mines 4wd, but I had the same problem. It ended up being the TTB bracket for the passenger side had broken 3 of the 4 bolts/elongated holes. Had bad tire wear on the passenger side also. Not sure of the brackets on the 2wd, but check it anyways. BTW, I had it aligned at several shops over about 1-1/2 years, no one noticed it. I had my son turn the wheel while I looked and notice the whole thing was moving side to side.

Put a 4" lift w/pitman arm on it, now it is the tie-rod end on the pitman arm moving but only when a tight turn at slow speeds.

 

[Titojeep]

New UPDATE - So I found a loose bolt on the stationary side of the driver side I beam bracket. That took care of the larger pop, however didn't notice ( i guess because of the louder pop) that there was also a smaller pop. Still looking fot that one. I followed the TSP procedure, but no luck first time around on the rivets.

 

[94f450sd]

Pop your hood and tighten the top fender bolts next to the hood hinges.thought i had bad radius arm bushings till i tightened those fender bolts.