Reply
 
Thread Tools Display Modes
 
Old 05-09-2018, 09:42 PM   #1
Senior Member
 
SierraHawk's Avatar
 
Join Date: Jun 2009
Posts: 196
Dana pro 60 new inconsistent heavy "clunk" when turning

'03 E350 SMB with Dana ProRock front diff. When turning a corner at 5 to 10 mph I can hear a distinct solid metal to metal clunk. The sound lasts just a second and can be heard while sitting in the drivers seat. There is no significant, corresponding vibration of the steering wheel. The sound does not happen every time I turn and can be triggered by braking hard at speeds below 30mph.

The van steers and tracks well. No crashes or running over large objects in the past 7 months. Calipers are bolted on, wheels are torqued to spec, shocks are not leaking and bolted in place, no play in the hub assembly (6 years ago I had an outer bearing disintegrate) and all of the suspension and steering components appear to be OK - no endplay or looseness.

I do not know what a failing rack and pinion would sound like but the steering fluid is good. Need more information? Any idea where to look?

Thanks in advance.
__________________

SierraHawk is offline   Reply With Quote
Old 05-10-2018, 07:11 AM   #2
Member
 
Join Date: Mar 2014
Posts: 47
I don't think any of the E-series vans have rack and pinion steering, so it's probably not that.

I would check track bar, ball joints, and radius arm bushings. If you're not familiar with all of those, it might be easiest to take it to a shop that specializes in front end repairs and rebuilds. I bet they can figure it out pretty quick.
__________________

__________________
2012 E350 EB Passenger V10
MG/Expovans full exterior and interior
ohsix is offline   Reply With Quote
Old 05-10-2018, 07:13 AM   #3
Senior Member
 
boywonder's Avatar
 
Join Date: Jul 2013
Location: So Cal
Posts: 2,976
ball joints
__________________
2008 E350 RB passenger 4WD SMB penthouse
2013 KTM 350 EXC
2008 KTM 250 XCF-W
2000 KTM 200 EXC
2003 Honda Element
boywonder is offline   Reply With Quote
Old 05-10-2018, 08:25 AM   #4
Senior Member
 
Join Date: Jul 2011
Location: Flagstaff, AZ
Posts: 1,672
^^^Sounds like a ball joint to me but could also be a bad U Joint.
__________________
2005 E350 RB 6.0 PSD for extended fun
1989 Landcruiser FJ62 for local fun
2011 VW TDI Golf for hwy fun
JoeH is offline   Reply With Quote
Old 05-10-2018, 11:09 AM   #5
Senior Member
 
arctictraveller's Avatar
 
Join Date: Mar 2013
Posts: 2,898
My front end uses leaf springs, and when turning, the leaf springs "fan", that's to say they slide across one another a bit, and that causes some loud "clunk's" as they tend to stick then release. It's been going on for years though and besides the noise it's not a problem. Just a thought...................
__________________
Arctic Traveller
KC6TNI
2001 GTRV
Advanced 4wd
Agile Ride improvement package
www.arctictraveller.com
arctictraveller is offline   Reply With Quote
Old 05-10-2018, 05:43 PM   #6
Senior Member
 
SierraHawk's Avatar
 
Join Date: Jun 2009
Posts: 196
I did not consider the leaf springs as a source for the odd sound. I will look at them more closely. I know that the shackles are good. The original track bar broke 4 years ago. It sounded like one of the long tubes on a door chime when it was rattling around. Bushings seem ok. Had the ball joints checked 6 months ago. Looked OK but 1500 miles might have made a difference. Ball joints are a real pain in that I do not get more than 50K out of them. Looks like I've gotten over 60K with this set. NAPA I think. Will jack it up to make sure. I cannot see any unusual movement in the tie rod or pitman end pieces. All of the fittings have been greased. I know that because the guys do not wipe off the excess. The mess is reassuring.
SierraHawk is offline   Reply With Quote
Old 07-01-2018, 12:19 PM   #7
Junior Member
 
Join Date: Mar 2016
Posts: 29
Garage
If you are going through ball joints that often you might try replacements from Dynatrac.
Are you sure the noise is coming from the front. We had a similar sounding noise for years and only at low speeds. We live an a semi-remote area but found a great mechanic. The problem turned out to be loose clutch discs in the rear diff. If you can reproduce the noise at slow enough speeds get someone to walk along outside while the noise is active. It was very hard for us to determine where the noise was coming from while driving. Turned out the discs had come loose (broken) and were rubbing against the differential case. Basically the entire rear diff needed a rebuild including the case. At the recommendation of our mechanic we had him get a Jasper rebuild Dana 60. No more clucking and a smaller bank account..
darryldickie is offline   Reply With Quote
Old 07-04-2018, 06:11 AM   #8
REF
Senior Member
 
REF's Avatar
 
Join Date: Jan 2009
Location: Boulder, CO.
Posts: 1,798
Send a message via MSN to REF
If it turns out to be the ball joints, X2 on the Dynatrac units, more $ but will last. Put them on our rig at least 60K ago and should last a while longer and are rebuildable.
__________________

__________________
'03 Ford E350 7.3L Diesel
(de)SMB'd Custom RB-50
Quigley 4X4 w/Deavers & Agile Offroad's R.I.P. package
CCV High Profile Pop Top
REF is offline   Reply With Quote
Reply

Tags
front end, noise

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off

» Sportsmobile Registry

DADDOZR

REDOVAL

Agnes

alta825
Add your Sportsmobile
Powered by vBadvanced CMPS v3.2.3
Disclaimer:

This website is not affiliated with or endorsed by Sportsmobile SIP or any of its affiliates. This is an independent, unofficial site.


All times are GMT -6. The time now is 03:36 AM.


Powered by vBulletin® Version 3.8.8 Beta 4
Copyright ©2000 - 2019, vBulletin Solutions, Inc.