1. Those cv axles do look like they have a sharp angle?? if you still have the old cv shafts, take the inner boot off and make sure they were not rubbing on the inside ( shaft hitting the inner hub. shinny mark on shaft) 2. Monroe Mag shocks I put on customers truck did get replaced under warranty for making noise years ago. Looks like Monroe's on yours and look pretty old. just another idea.

 

Just a thought...are you sure it is suspension issue??
Have you taken the serpentine belt off...& gone for a short drive & see if it is still there?
Just wondering if the belt tensioner is just a tad weak?

If that isn't the issue, have you looked at the engine and tranny mounts?

 

Ok! The torsion bars were cranked all the way up! For some reason the previous owner must have done it.
So now I turned them out and made the CVs pretty even across. What's this going to do to my alignment?

The shocks are only about 2yrs old but look 10. Michigan winters are rough

 

1. I would lube those bolts up good before turning them. 2. Put truck on level ground, and look at the wheels,( if ya have a 3ft level) put it up against the tires (12:00 to 6:00) and see where the bubble is. Do your adjustments ( same amount of turns on each side) take for a ride around the block and stop in the same place. Mark the ground or black top w/chalk. take your level and see if its the same as before. if it is ,then no alignment needed. POOR MANS WAY!

 

If you already did it, put truck on level ground, 3ft level, check r-rear tire and r-front tire should about the same and do the same for left side, Each front and rear on the same side should match! if way out then get an alignment

 

Thanks for the quick reply RevBiker! Yes PB blasted before I attempted to turn them. A coworker has a 03' FX4 so I went off of his as far as how far the bolt is turned out.

My concern is about two years ago when I replaced all the front end parts I just bolted on the new Moog upper control arm with out the caster/camber cam kit. I'm wondering if I need them now? Alignment shop seemed to get it with out them
When I get home I'll throw the level on it see where I'm at

 

Here's an interesting question... I measured my coworkers 03' FX4 wheel clearance from center of rim to bottom of fender. His measures 22 1/4". Mine measures 23 3/4" after I have turned mine down a bit. The question is how can both trucks have the torsion bar adjustment bolt turned out the exact same distance but yet my truck sits that much higher?

What is the factory ride height for the 97-03's with the off road pkg.
Trying to solve one problem and find another

 

you could have aftermarket torsion keys and cranked adjustment bolts



You said you did sway bar bushings? What size did you order? Should be 29mm

 

Sway bar bushings are original. I just did the end links with Moog #K8772
Just ordered the Moog camber/caster bolt kit. I'm going to put them on and lower it down to 22 1/2". I already have a appointment Friday at the Ford dealer for the alignment. Tackle this problem so I can get back to my original issue. I sure hope this long thread helps some buddy some day

 

Did the noise stop?

 

Sounds like it's still there. When the dealer has it on the rack I'll have them check the pitman and idler arm

 

Just checking to see what ever happened to your noise issue?

 

I have since sold the truck. But it still made the rattle in the front end the day I sold it. For the life of me I could not figure it out. The entire front end was brand new with the exception of the lower control arm and sway bar bushings.

I now have a 07' with a whole new set of demons...