Front End Woes - Addco Sway bar issues / Front End Clicking

[kmastl]

This is really a two part problem to my knowledge. These occurrences are independent of each other. Looking for suggestions as I will be tearing down the front end on Friday.

I will start with my biggest issues the front end clicking.
I have had about 1/2 dozen different people look at my front end and NONE of them can pinpoint exactly where the clicking is coming from. This problem started when I took apart my struts to cut the springs. The clicking/binding noise happens when I use my brakes or go over large bumps. I seems if there is any lateral movement on the CA's/Spindle like going over the curb on the end of a driveway, speedbumps etc. I did not mark my coil on spring assembly when I tore it apart so it was aligned by eyeballing it and sticking it in there <<< area of concern. I have been told to take them apart again and use white lithium grease on the boot where the spring sits... so I did. With no result.
• I will try and get a video of the phantom click this week
• I will post a bunch of pics of how every thing went together/apart on Friday.


- One note I am currently driving with no front sway bar so it sadly wan't the cause of my clicks.

[Blackened300a]

This is really a two part problem to my knowledge. These occurrences are independent of each other. Looking for suggestions as I will be tearing down the front end on Friday.

ISSUE #1
I will start with my biggest issues the front end clicking.
I have had about 1/2 dozen different people look at my front end and NONE of them can pinpoint exactly where the clicking is coming from. This problem started when I took apart my struts to cut the springs. The clicking/binding noise happens when I use my brakes or go over large bumps. I seems if there is any lateral movement on the CA's/Spindle like going over the curb on the end of a driveway, speedbumps etc. I did not mark my coil on spring assembly when I tore it apart so it was aligned by eyeballing it and sticking it in there <<< area of concern. I have been told to take them apart again and use white lithium grease on the boot where the spring sits... so I did. With no result.
• I will try and get a video of the phantom click this week
• I will post a bunch of pics of how every thing went together/apart on Friday.

ISSUE #2
I am having trouble when the sway bar moving side to side and having the MOOGS endlinks hit the rotors on my front SB. I think the bushing may be worn, the paint where the bushings rub is gone. I grease them every three months or so with "ford lincoln mercury branded valvoline branded moly fortified multi purpose greese". Once I left them go to long and it started to click and there was not enough grease. Also I am one of the caps on the endlinks is missing can I order a replacement? or does anyone have a good idea for something else to use? Also where can I get a new bushings for this sb?

- One note I am currently driving with no front sway bar so it sadly wan't the cause of my clicks.

I'm curious what the result is because my Moog end links also rub and I have the click when I stop and go which nobody can find and I greased everything while making sure all is tight and I still can't figure it out. One mechanic told me he saw on a expedition that the K member clicked and his repair was to loosen it up and put some grease on the top of the member between the frame and that solved it. I haven't tried it yet on my car so I'm not sure if thats the fix.
I also had my front end aligned and the end links still rub. I think the Moog are just a little too fat in design compared to the OEM. Thats what it looked like to me when I last looked at them 2 weeks ago and saw the rubbing.

[kmastl]

I'm curious what the result is because my Moog end links also rub and I have the click when I stop and go which nobody can find and I greased everything while making sure all is tight and I still can't figure it out. One mechanic told me he saw on a expedition that the K member clicked and his repair was to loosen it up and put some grease on the top of the member between the frame and that solved it. I haven't tried it yet on my car so I'm not sure if thats the fix.
I also had my front end aligned and the end links still rub. I think the Moog are just a little too fat in design compared to the OEM. Thats what it looked like to me when I last looked at them 2 weeks ago and saw the rubbing.

Did you notice if you sway bar moves left to right? It looked like mine was sliding through the bushing and one of the guys that looked at my car said that the bushing should hold it into place from going left to right.

[breeze]

Gottta be the lower control arms. Mine has seemed to stop the clicking. Replaced both sides atleast twice.

[kmastl]

I had it up on a rack this past weekend and we came to the conclusion that is coming from the upper CA area. I can FEEL the popping most right above the three bolts that are atop the strut. I will try and get that video up tomorrow. I have been battling this thing for 5 months.

- btw the click started when I took the struts off to cut the springs so it has to be something I did

Gottta be the lower control arms. Mine has seemed to stop the clicking. Replaced both sides atleast twice.

[sailsmen]

Go back to OEM and see what happens.

[fastblackmerc]

You should be using full synthetic lube with the aftermarket sway bar / bushings.

[burtreynolds]

I had the clicking until I removed my swaybar (experimental). I have not put the bar back on, but I am cut springs as well (one coil)

[kmastl]

GOOD NEWS. I have fixed the clicking noise! and installed the stock front sway bar. I hope the end links stop rubbing.

It was these two bolts in the pictures.. The ones directly above the upper control arm toward the front of the car. I have never touched these bolts but took it apart tonight goofed around for about an hour. The fix was a quick spray with white lithium grease, didn't even have to loosen the bolt.

It seems odd that this happened at the exact time I cut the springs. Must have been the change in geometry that caused a new stress to that spot IDK.

[cougar9150]

It seems odd that this happened at the exact time I cut the springs. Must have been the change in geometry that caused a new stress to that spot IDK.

Not really, you changed the geometry of your front suspension. Since you cut a coil the CAs sit at a different angle now.

Did you torque down the CAs with the full weight of the car resting on the suspension? If not they may been binding but the lube loosened them up.

I have the same issue with the sway bar moving. It took out the ABS sensor cable on one of the brand new hubs I had just installed. 1/2 mile later it wad back to the store for new stub.

My car had the Addcos when bought it but the bushings were never greased. I was doing an overhaul of the suspension and used the ES bushings w/grease fittings.

I got standard ES bushings, lightly greased them, and have clamps on the bar on the wheel side of each bushing. Going to order tbe improved bushing/bracket kit from Addco and hope it works. May blast the bar and get it powder coated, once I order the bushing kit.

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