Hey guys I did a search for this a few weeks ago, and there were quite a few of us having this issue but no definitive solutions. So I thought I'd post my experiences to help you guys out.

Truck - 2004 FX4 Screw, 1.5" level kit, BFG TKO 33's. 49K miles.

Problem - Weird clicking, almost metallic grinding clicking noise while making turns. Not at full lock, just while turning at speed.

Diagnosis: At first, thought it could be CV joint, bad angles on the knuckles etc. Took to Dealer, found no issues with angles or any steering component whatsover. Dealer could not find source. Lubed boots, noise persisted.

Dealer tried engaging and releasing 4WD system to make sure components were locking properly. All looked good yet noise persisted.

Took to buddy at alignment shop for second opinion. Same thing at alginment shop, even had aligned. Noise persisted.

As a last resort, I checked the boards again and someone recommended rotating the tires. Did that.

I'll be damned. No more noise.

Guys I don't know what it was, but it hasn't made the same noise in over 3 weeks now.

Hope this helps, and if anyone has any insight, please feel free to shed some light on this. I still can't wrap my head around what the problem was.

TXScrew

 

This is kind of an "out there" thought, but did you have something stuck in the tread of one of your tires?? That's happened to me before; I had a screw stuck in my tire, near the edge of the tread. Everytime I'd turn left, it would click. The "click" turned out to be the screw head hitting the pavement.

 

Nope...checked that right off.

 

Just a thought. Think it could be a steel belt becoming separated in the tire? 50k miles is a lot for any tire.

 

Im having this exact problem i think. when i turn right it clicks and makes a metal sounding popping noise. is this what you heard?? ill go and get rotated tomorrow to see if works.

 

I got the same problem, I'll rotate and see if it works!! I also had mine in the shop and in the dealership and they told me that any truck as heavy as these new fords is going to make clicks when it turns!!!

 

My buddy is having the same issue with his 05 FX4 and the dealership told him that the leveling kit was causing it as it was making the angle too steep.

 

The tires only have about 10K miles on them. Sorry I didn't clarify that point in the first post.

 

I had the same problem with my 2000 F150 and it turned oput to be the rear emergency brake shoes. Check them. Try rocking the truck back and forth while in park and the engine is off, you may hear the clicking sound. It was hard for me to belive that the E brakes were making this noise but all I did was replace the shoes and hardware which was a conch and the noise has been gone for months now! Good luck.

 

I had Boyd Coddington wheels on my ranger and the center caps clicked like a bad bearing, loosen em up and re tighten and it would stop. embarrassing at shows...