Clunking Sound

[05VAroush]

I keep hearing an occassional clunking sound that's coming from the front suspension. I hear it when driving on uneven roads, cracks, etc. I've looked at everything, sway bar, struts, etc. I also made sure all bolts are tight. The struts were replaced about 2 years ago because the first ones were defective. The car is a 05Roush Sport with Roush suspension. I'm scratching my head on this one, any ideas before I take it to the doctor?

[1Bad06Roush]

Mine's doing the same thing. It sounds like its coming from the passenger side and sounds like an exhaust hanger broke. I'm going to put mine on a lift sometime next week and take a good look.

[13 MIKE]

The spring isolaters on the bottom of the spring are not indexed correctly. I had to redo mine after i swapped suspension.

[gpfordjoe]

that does sound correct but really could be a number of things did it start after you had the others replaced

[1Bad06Roush]

Mine are indexed right, that was the first thing I checked. This didn't start until about a month ago.

[01roushstg1]

Originally Posted by 1Bad06Roush

Mine are indexed right, that was the first thing I checked. This didn't start until about a month ago.

You don't drive it enough

[EAGLE 5]

did you (or people who did you suspension) reuse the strut insulator up top? If so it may have failed with the lowered suspension and it's giving you noise. That's apparently a common thing with the S197 Mustang. It is best to upgrade to stiffer GT500 rubber insulators/mounts or get aftermarket camber plates altogether.

[RED ROUSH WA]

Originally Posted by 1Bad06Roush

Mine are indexed right, that was the first thing I checked. This didn't start until about a month ago.

Make sure you check the front swaybar end links(attaching to struts) with a wrench.
These sometimes seem tight but they still can move.
This is what I found when my Roush making this clunking noise.

Originally Posted by EAGLE 5

did you (or people who did you suspension) reuse the strut insulator up top? If so it may have failed with the lowered suspension and it's giving you noise. That's apparently a common thing with the S197 Mustang. It is best to upgrade to stiffer GT500 rubber insulators/mounts or get aftermarket camber plates altogether.

Next check on this ^^^^.

[1Bad06Roush]

Originally Posted by 01roushstg1

You don't drive it enough

You sir have a very valid point!
Thanks for all the ideas, sounds like I have a little work to do. Just in time for cold weather too! Whoo hoo!!!

[ruarmed2]

Try removing your billett strut caps, the large ones, have seen these ground out on top of the strut tower over bumps and make a terrible sound

[05VAroush]

I checked the exhaust system and no movement there. I installed a MRT H-pipe about 4 months ago, but the noise started maybe 2 weeks ago. I'll check the sway bar end links with a wrench too. I did reuse the strut insulators after the upgrade, maybe it failed. Also, I removed the billet strut caps, but didn't see any problem there. I'll take them off completley and drive around to see if that's the problem. Thanks for all the suggestions!

[jack1.1]

The doughnuts are called upper strut plates and they should not fail unless you have say over 50k miles and have driven rough. Plus you say it's a clunking sound in lieu of a popping sound. An upper srut mount would be a pop vs. a clunk.

Suspect it to be in the lower, not upper parts of the syspension or like others suggested in the exhaust.

Jack

[toolttime]

There is a TSB on this 07-18-2. I had to do on mine. If the car is still on warranty it is free. Mine was not and it cost me 225. for the parts.
Here are the ford part #'s you need to fix it.

2 - AD1062 BRACKET
8 - W520112 S440A NUT
2 - W520215 S440 NUT
4 - W709870 S439 BOLT
4- W711091 S900 NUT
2 - N807144 S440 NUT AND WASHER

[BratFireman]

Had this issue also. Front sway bar was loose.

[sbr2005]

ive had the strut mounts make noise,they did that if you sit still and turn the wheel back and forth,roush has a recall on the front struts for the link mount seperating. also there is a ford tsb for the crossmember where the exhaust is supported that may make noise.

[Rangersfan]

Sounds like upper strut mounts or possibly the nuts on the swaybar endlinks are loose. Those are the most common cause of noise in the front-ends that I've come across.

[Iflyagfour]

Sounds like the TSB that came out for the Cobras.

[1Bad06Roush]

Originally Posted by Rangersfan

Sounds like upper strut mounts or possibly the nuts on the swaybar endlinks are loose. Those are the most common cause of noise in the front-ends that I've come across.

I took it in yesterday and threw it on the lift. After checking the sway bar and lubing the bushings (getting rid of the syrup that Roush used), I still have a problem. So it's gotta go in for some warranty work, we all suspect it's a damaged strut. We'll find out shortly, couldn't have happened at a better time either, warranty expires this month

[innrkid]

I had this exact issue this summer.

If you had had the front calipers off, or have not checked them, you might want to try that.

Mine were off when I replaced the rotors and pads. There are two recessed bolts that need to be tightened real well or they will knock.

Mine would sound like something bottoming out and was intermittent. It was slight and intermittent which was a pain in the ass to track down.

Good luck.