Im stumped on this suspension noise...
 

Ive been chasing this sound for 2 years now! Its a crunching/clunking/popping sound from front end with braking, or going over bumps at speeds lower than 15mph... I did tons of research and found a lot of information on a correct repair.. However all has been unsuccesful for me.

I have already replaced the steering rack gear tubes, and control arms with new control arms. Yet the sound is still there!

Im going to try to replace the stock strut bushings with poly ones and see if maybe thats the problem.

Im wondering if anyone else here has had a similar sound, and what their diagnosis was?

Did you check the sway bar bushings and end links.

The sounds are not symptoms of endlinks, and the endlinks are in perfect condition. I appreciate your advice though! This sound is driving me nuts!

Do you remember when it first started? I remeber having a noise and it was because the anti rattle clips where installed wrong on the calipers. Kind of hard to troubleshoot unless you are physically there hearing it.

Its been there ever since I bought it used back in 05 of this month. What anti-rattle clips are you talking about? There are clips in the caliper bracket that hold the pads in place on the bracket? Is that what your refering too?

The sound is loud and can be felt in the frame of the car. Its sounds like rubber binding against metal or steel. I would describe it has a pop or a crunch. The sound is usually inconsistent also. Mainly does it when doing less than 15mph while braking to a stop, and going over bumps. Also if you have the wheel turned all the way, and start rolling from a stop, youll hear it pop once also.

On other mustang boards, I found people with the same problem, and it ended up being the control arm bushings(there is a Ford SSM on this issue also). Some people had the same symptoms, but it was the strut bushings. I have already replaced both... But problem is still present. I even narrowed it down to either the CA bushings or strut bushings before I even did research on it. But still no luck.

Im all out of suggestions best to check every bushing. My brother thought one of his vavles took a dump since he keeps hearing a loud ticking noise. After I heard it and look at engine I notice it was coming from the Alternator and sure enought the bearings were shot. Sometimes you need a fresh pair of eyes and eyes looking at the problem.

Motor Mounts or tranny mounts? I have it seems like the same problem you have and thats what I'm going to look at tomorrow.

No motor mounts would casue differnet symptoms.

Motor mounts would cause increased vibration while at idle in gear. Plus, this sound only happens when weight is shifted on the front of the vehicle.

I'm having the same exact problem it seems. Let me know if you have any luck.

if it only happens when weight shifts to the front then I'll bet one of your bushings in the back is actually at fault. I've gotten sounds that seemed like they were in the K-member and even the passenger side door that turned out to be in the rear suspension. For me it was binding from a bad adjustment on my PHB binding up the UCA's decelerating into turns. I'd give a serious looksee to all the bushings in back.

Another possibility is that your k-member itself has a loose attachment point (including the cross brace at the back of the oil pan). I've seen that in cars that have curbed themselves... they'll actually end up with the k-member moved and it'll get some rub under load.

Actually, I just found the problem a couple days ago. Poked a hole in the front lower ball joints, sparyed a bunch of grease. Drove, noise gone.

So any of you still looking for a solution, and your symptoms sound similar.. Try it, all you need is a bottle of lube.

I am really glad I found this post. I have the exact same problem, and have been trying to hunt it down. Was leaving me stumped as heck. I will now try that when I get back home, and hope it will owkr out.

Had the same deal.. Went to canada...popped a leak in the plastic upper intake manifold..took it to the ford dealership in Peterborough Ontario...also had some issues with that...they ended up replacing the steering rack...but 2 days after getting that fixed up...the noise as described came back..mine was a little worse..took it back to ford...they couldn't figure it out... drove back home to omaha,ne.. and had a guy look at it...just needed the hub greased up more..apparently new one was installed and ford never greased it!!!