Windstar front end - Single clunk at start up

Hello,
I own a 98 Ford Windstar 3.8 lit and has 200,000 kms on it.

I have been experiencing a single clunk noise in the front end. It only happens at the startup if the car was sitting for few hours.

I cannot repeat the same if I turned off the van and restarted again. It has to sit for 3-4 hours for the clunk to repeat.

I have replaced the following and it did not help.
Outer tie rods, Engine mounts - Front and back, Strut bearings, Stabilizer links, Subframe bushings, Sway bar and bushings (Metal sleeve welds are fine), Lower control arms, Front wheel bearings.

I am tired of this clunk now. It happens only once and is loud.

Please help.
Thanks.
Jay

Is the vehicle changing directions at start-up? Are you parking stopping forward, but starting up in reverse for example? If so, the brakes may be your noise maker. Do you always use the parking brake? (You should.)

Is the vehicle changing directions at start-up? Are you parking stopping forward, but starting up in reverse for example? If so, the brakes may be your noise maker. Do you always use the parking brake? (You should.)

I always park stopping forward and Yes, I am changing the direction when backing out. The clunk noise comes as soon as the steering goes 10 o' clock position. It only happens once.

I always use my parking brakes. The clunk seems to be from fron passenger side.

Please reply.
Thanks

..... The clunk noise comes as soon as the steering goes 10 o' clock position..........

Please reply.
Thanks

Ah ... another clue! I don't take brakes off the list ... but now put the steering system on top of the list. Something is loose ... either from wear or improperly assembly. Be sure to re-inspect the rack mounting bolts, the links, inner and outer tie-ends .... and all around the top of the struts; in particular, the shock-top anchorage. Check lower control arms. Check motor mounts and sub-frame mounts.

Ah ... another clue! I don't take brakes off the list ... but now put the steering system on top of the list. Something is loose ... either from wear or improperly assembly. Be sure to re-inspect the rack mounting bolts, the links, inner and outer tie-ends .... and all around the top of the struts; in particular, the shock-top anchorage. Check lower control arms. Check motor mounts and sub-frame mounts.

I will check the rack mounting bolts today evening.
Are you suggesting the rear brakes or the front ones...and what to be looked in particular for brakes.

The subframe bolts are good as I have replaced the 4 bushings and new bolts in February this year and the allignment was done in March after I changed the outer tie rods.
I have just replaced the motor mounts yesterday.


Thank you for the suggestions. I will check the rack bolts today and post my findings.

Regards,
Jay

Be sure to check the strut "tops"....

If it is the brakes, its because they need prescribe lubrication. Drum brakes are probably more of a problem than discs.

I have just finished checking the rack mount bolts and they did not even move. So it is not the rack being loose.
I will now check the strut tops.
Thanks

... about those rack bolts. They are splined, so you will not be able to turn them. Its the nuts beneath that do the fastening ... over 100 ft lbs, IIRC.

Good luck!

... also check the lower control arms. Could be a worn pivot knuckle or rubber bushings. Loose bolts/nuts.

I have checked the strut tops and the lower control arm. All is tight and nothing moved.
I also replaced the rear brakes.
The clunks is still present.
Thanks

Wow, you have a mystery indeed. Any chance you could have an associate do the first few feet of driving some morning ... while you hang over a fender with your head underhood, or near a wheel ... just to get a better idea?

Finally the mystery is resolved. I have replaced both sides CV joint assemblies and also the center Hubs.
The clunk is gone.
The noise was either from inner cv joint on passenger side or from the hub as the brake rotor might be slipping between the hub and wheel.

Anyways my death star is noise free and is Windstar again.
Regards,
Jay

Good ... thanks for feedback!