Suspension Clunking Noise on Driver’s Side

[Sleeper 7]

Ok, I think I may have solved my own mystery, thankfully before embarrassing myself at the mechanic (just in front of you all); but maybe I can serve as a cautionary tale. The clunk had gotten so bad so quickly that when I got to work, I pulled out the cheap aftermarket floor mat I had on the drivers side (My Maverick shipped without the floormats and I'm still waiting on them to come in) to see if there was any evidence of what was hitting under my feet. I couldn't see anything there or in the wheel well that could be causing the noise/sensation. I put the mat back and went in to work. I had no idea what it could be (CV joint?) but made an appointment to get it checked.

However, driving home that evening - the noise had completely vanished - nothing - as right as rain. Must be cold related I thought. This morning was cold - this would do it. Still nothing. Still perfect. WTF? Got to work and this time took a GOOD look up under the driver side foot well. Where the steering column meets the floor, part of the steering mechanism is exposed and there is a linkage there with a large, exposed bolthead that when you turn the wheel, spins around and around. And if you get a cheap plastic floormat jammed up against it - that bolthead will catch the edge of the mat and go "clunk" when you turn the wheel enough. Forehead slap. Now to cancel that appointment....

I had something similar going on with my old Fiesta. Loud knock when temps went below 20. The colder it was the louder it got. Sounded like the struts were gonna come thru the hood . It was the material Ford used for the bushings on the drop links. When cold the nylon bushings would shrink causing the noise. The only fix is to buy some after market Moog drop links with grease fittings. Your dealer will just replace the links with poorly engineered new parts to get you thru the warranty period. After that your paying the bill anyway and Ford wont redesign the part. They just keep replacing bad parts with more bad parts.

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[207maverick]

Looks like I may have an issue where the CV enters the transmission. The first video is the front passenger side (with no clunking issue or wobble), the second is the driver’s side where I’m getting the clunking noise and wobble). I know a little movement is normal, but this seems like a bit much.

 

[privatelogic]

Lariat AWD has same issue. Took it in to the dealer and it has to be looked at by a 'certified Ford mechanic' because it's related to steering. What?

They've had it for nearly two weeks and nobody's touched it. Super frustrating. I guess there are no certified mechanics in the DFW area

 

[IdahoDirtFarmer]

Funny this thread comes up suddenly. I've got 550 miles on mine and the last couple days there's a thunk under it. Only happened twice so far, once each day. Both times at low speed, driving straight, about 10-15 mph. Sounds and feels like when a fist sized rock bounces up under ya while tooling around in the desert. Looked all over under it can't see or feel anything loose.

 

[207maverick]

Funny this thread comes up suddenly. I've got 550 miles on mine and the last couple days there's a thunk under it. Only happened twice so far, once each day. Both times at low speed, driving straight, about 10-15 mph. Sounds and feels like when a fist sized rock bounces up under ya while tooling around in the desert. Looked all over under it can't see or feel anything loose.

At low speed, if I turn the wheel (slightly) quickly to the right, and then back to the left, it causes the clunk. I think it’s an issue with the case bearing/bushing they stabilized the CV. More discussion and other folks with similar issues in this thread https://www.mavericktruckclub.com/forum/threads/shimmy-wobble.25898/

 

[IdahoDirtFarmer]

At low speed, if I turn the wheel (slightly) quickly to the right, and then back to the left, it causes the clunk. I think it’s an issue with the case bearing/bushing they stabilized the CV. More discussion and other folks with similar issues in this thread https://www.mavericktruckclub.com/forum/threads/shimmy-wobble.25898/

Mine was just driving in a straight line going down my driveway. It almost sounded/felt like a hard downshift in the transmission. I'll double check the CV area though.

 

[privatelogic]

Got an update this morning.

"Looks like we are having to replace a shock and a couple of one time use hardware to fix your concern. We ordered parts on Tuesday and it looks like they're set to come in late today. Hoping to have your vehicle repaired by tomorrow 5pm."

I really hope this is a fix. I can't let go of my truck for two weeks every time there's an issue. Maybe that's part of Ford's plan to lessen the warranty repair work they'd have to do

 

[207maverick]

Mine was just driving in a straight line going down my driveway. It almost sounded/felt like a hard downshift in the transmission. I'll double check the CV area though.

Same symptoms here. I’m just wondering if you get a clunking noise (like something is not held in/secured right) as I do. My theory is that the case bearing/bushing is bad, which would cause excessive movement, making the CV wobble outside normal movement

 

[IdahoDirtFarmer]

Same symptoms here. I’m just wondering if you get a clunking noise (like something is not held in/secured right) as I do. My theory is that the case bearing/bushing is bad, which would cause excessive movement, making the CV wobble outside normal movement

That sounds plausible. It's just one singular clunk each time it's happened for me. Just going off the sound, I'd say yes, it does sound like something isn't tight. I haven't had a chance to pull it into my shop and crawl around under it yet. I was hoping to this weekend.

 

[privatelogic]

Well, it was the shock. Glad to have my Mav back!

 

[Dmack]

Same clunking sound from drivers side, almost sounded like a broken strut mount. Replaced shocks, still there. Noticed a small amount of play in the drivers side cv axle however slight play is normal however I was still concerned. Ordered some new greaseable end links because I noticed the factory ones look like a one time use part. Guess what sound is completely gone! Thinking dealerships know these end links are garbage but will sell you on a strut because their replacing the end links anyway. If your going to be using this mini truck off road I'd recommend swapping out your end links. If anyone's interested I used Mevotech Front & Rear Sway Bar Links For Ford Bronco Sport 2021-2022 off ebay.

 

[Montana]

Same clunking sound from drivers side, almost sounded like a broken strut mount. Replaced shocks, still there. Noticed a small amount of play in the drivers side cv axle however slight play is normal however I was still concerned. Ordered some new greaseable end links because I noticed the factory ones look like a one time use part. Guess what sound is completely gone! Thinking dealerships know these end links are garbage but will sell you on a strut because their replacing the end links anyway. If your going to be using this mini truck off road I'd recommend swapping out your end links. If anyone's interested I used Mevotech Front & Rear Sway Bar Links For Ford Bronco Sport 2021-2022 off ebay.

Yea it drives me nuts that everyone has switched to these one time use parts. A little bit of grease during routine PMCS goes a very long way.

I have the noise too (Passenger side only over major bumps). I've been under multiple times and not noticed anything out of the ordinary. Some have reported the noise going away after a retorque of suspension components and I'm about to add that to my list of things to do. If that doesn't solve it, I hate to admit it, but I may let the dealer get it on a lift and do some warranty work under there.

I'd kill for my own lift.

 

[Thrashdragon]

I’m having the same issue when I’ve turned left I’ve had it jump forward slightly almost like I was hit but I wasnt

 

[Ford Motor Company]

I’m having the same issue when I’ve turned left I’ve had it jump forward slightly almost like I was hit but I wasnt

Hey, Thrash! I can take a closer look into this noise concern you're experiencing if you like. Can you send us a private message with your VIN and the name/location of your service dealer? To send a private message, just click on our username and select "Start Conversation".

 

[Sleeper 7]

Same clunking sound from drivers side, almost sounded like a broken strut mount. Replaced shocks, still there. Noticed a small amount of play in the drivers side cv axle however slight play is normal however I was still concerned. Ordered some new greaseable end links because I noticed the factory ones look like a one time use part. Guess what sound is completely gone! Thinking dealerships know these end links are garbage but will sell you on a strut because their replacing the end links anyway. If your going to be using this mini truck off road I'd recommend swapping out your end links. If anyone's interested I used Mevotech Front & Rear Sway Bar Links For Ford Bronco Sport 2021-2022 off ebay.

They have been using these junk links on the disposable vehicles for years. Not enough grease in them and when the grease pushes away from the joint its metal to metal.

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