Suspension Clunk!, 98 Windstar, 120k

I have a 98 Windstar (120k) that makes a clunking noise when I back out of my driveway while turning the wheel. Also, my friend has a 96 Windstar (140k) that does the exact same thing, except more pronounced. I tried to fix the ’96 over the weekend by the replacing the lower control arm. The ball joint in it seemed loose when I was under the van feeling around. But alas, that did not solve the problem. So, I went under the van again, but couldn’t find any other ball joints that were seemingly worn. I’ve done quite a bit of suspension work on other cars and wouldn’t write in except that I have 2 windstars doing the exact same thing, and I’m unable to diagnose it on both! the funny thing about it is that it’s only noticeable when I’m backing out of my driveway. Any ideas?

Hello-

When's the last time you replaced the struts ??

If everything else on the front end is tight - sounds like it may be the strut bearing plate.

Good Luck-
Glenn

before doing the struts I'd really look at the health of the sway bar bushings. I live in a pretty pot-holey town and I go thru sway bar bushings about every 20k. If it's not those, wiswind has a link in his sig line that shows pictures of how the sub frame bolts have broken the weld leading to the double clunk noise. If you haven't replace the sway bar bushings though, they're likely really in need.

Piper

check this link too. http://www.automotiveforums.com/vbulletin/showthread.php?t=920395&highlight=sway+bar+bushing

I haven't replaced the struts or thrust bearings. I will check out the sway bar bushings though. Anyone know if these bushings are a big job?

no it's pretty simple. I've done it for both sides in less than an hour. Do a search it'll come up.

instead of welding they have a repair kit from rock auto to solve that loose collar in the subframe. I had the first side welded a while back, that was before the kit came out. The second side the drivers side has the kit in it and it is a lot tighter. The side that was welded is still tight but has a tiny bit of movement. If i have that problem again i will go with the repair kit again for that side.

what does rockauto call this kit?? I looked and couldn't find it. Do you have a link?

P

I think that this is it.....under the 1996 windstar

http://www.rockauto.com/catalog/x,carcode,1141636,parttype,10402

It is called "Cross Member Repair Kit"......under "suspension" in the parts menu.

Other "clunk" causes that I have had are tie rod ends (inner/outer) sway bar links, and lower ball joints.

In fact.....mine is in the shop right now having the sway bar links and the passenger side lower ball joint replaced.....
The factory original ball joint lasting over 211K miles, 13 years is certainly good service.
The driver side lower ball joint was replaced 3 years ago at 183K miles.

The sway bar links were replaced 3 years ago......but they were the nylon ones......and this time they are installing the Moog brand with the grease fittings.

So now....I will have grease fittings for my outer tie rod ends, lower ball joints, and sway bar links.

For front end "clunks", unless you are experienced....it is best to have a trusted mechanic check out your vehicle.
I do this.....and it is well worth the time and minimum expense to have a "safety inspection" done....as I am not a experienced mechanic.
I also prefer to leave some repairs to folks who know what they are doing.

The radius arm bushing working loose in the sub-frame is a common "clunk" cause.
I have had mine welded twice.

The location of this is shown in this picture.

http://rides.webshots.com/photo/1324733856011220610fHHHrI

A link to the picture that a member sent me of the weld job on their vehicle....
http://rides.webshots.com/photo/2527378610011220610BgMIon

Of course, they put the outer bushing and nut back on.

If the clunk you're hearing sounds like it's coming from under the van, and can happen when the steering is not changing, then I'd suspect the subframe attachment bolts. I started having this problem when my transmission work was first done, requiring that the subframe be removed to replace the transmission. I find that this clunk sound seems to occur when braking, turning, or accelerating. It seems to be the subframe shifting as the forces of driving push it in different directions.

Check the torque on the subframe bolts. That's a free and easy repair. Also, be sure that your pinch bolts on the steering knuckles are tight. I once had a similer sound because of under torqued pinch bolts.

I ran my first set of sway bar bushings to 200 k mile and they didn't really need to be changed when I did it, although there was some wear on them. It wasn't hard except for the limited clearance for the bolts. My Windstar is a '96.

Not much help, but I had the clunk on the drivers front suspension for a long time. Ford said it was evry common for rocks and crap to collect in the bottom of the spring. I believed them, but then I got smarter by reading this forum, but thats another topic. Anyway, last weekend I was udner the van changing oil before a long road trip and looking around I noticed the sway bar link on the drivers side had broken apart at the lower ball joint. I replaced both sides in about an hour with the Moog links with grease nipples. No more clunks so far! I guess what I am suggesting is that the joint could be screwed up, but has not come apart yet so it is not obvious. Mine broke at 143,000 km. I had just been there changing brakes two weeks before and everything looked fine. Obviously it wasn't. The two links cost me $100 total.