Front end knocking noise (video)

[Wet Willys]

I have a knocking noise in my front that's driving me nuts. It happens mostly over small chatter bumps. I've torqued everything, there doesn't seem to be any play in the ball joints or tie rod ends. Drag link ends have no play. Everything seems tight. I cannot seem to pinpoint it and it's making me crazy. I feel like it's something really obvious that I'm just not seeing.

2021 Willys gas
2.5" Clayton overland plus lift
Rancho geometry correction brackets
RPM 2.5 ton steering kit
Fox ATS steering stabilizer

The knocking noise is very apparent in the video. See what you think:

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[Vtur]

Have you checks swaybar end links or bump stop spacers?
Does the drag link bar has any rotational movement?

 

[Klicht87]

Have you checks swaybar end links or bump stop spacers?
Does the drag link bar has any rotational movement?

I was thinking the same thing with the drag link bar. I don't have any aftermarket kits on mine besides the 1.5 teraflex spacer but I've read in a few spots that aftermarket drag links seem to make some noise.

 

[Wet Willys]

Have you checks swaybar end links or bump stop spacers?
Does the drag link bar has any rotational movement?

I tried running with the sway bar disconnected - noise still there. Not much rotational movement on the drag link - maybe a few degrees at the most. I initially thought that's what was going on, so I stuck a GoPro under the truck and drove around to confirm. I was totally expecting to see the tie rod or drag link flopping around causing the noise, but it doesn't appear to be.

 

[Vtur]

I tried running with the sway bar disconnected - noise still there. Not much rotational movement on the drag link - maybe a few degrees at the most. I initially thought that's what was going on, so I stuck a GoPro under the truck and drove around to confirm. I was totally expecting to see the tie rod or drag link flopping around causing the noise, but it doesn't appear to be.

The drag link can flop within the single plane ball joint. My old stock one made that same noise on washboard trails.

 

[Vtur]

I was thinking the same thing with the drag link bar. I don't have any aftermarket kits on mine besides the 1.5 teraflex spacer but I've read in a few spots that aftermarket drag links seem to make some noise.

Yup. Mine Synergy has more than an inch up/down rotational play. I'm sure it'll makes ton of noise once the joint wears out.

 

[Wet Willys]

The drag link can flop within the single plane ball joint. My old stock one made that same noise on washboard trails.

The RPM drag link ends have anti-flop inserts, but that's not to say it isn't making the noise. There's not a lot of rotation though.

 

[CrazyCooter]

Look at the shock and caliper bolts? When that knock occurs, it sure liiks like the axle is hopping unconrolled. That's when the loose part noises show up for sure.

 

[Arisdocjk]

Did you check the torque on the upper and lower control arms?

 

[Wet Willys]

Did you check the torque on the upper and lower control arms?

Yep. Lowers torqued to 190 ft-lbs. Uppers to 85 ft-lbs.

 

[Arisdocjk]

Does it seem like it is on one side? Are you able to shake it up and down and re-create the noise while parked? Is there any noise just by turning the steering wheel back and forth while parked or is it just over bumps? Is it worse turning right or left over a bump or same as going straight over a bump?

 

[Wet Willys]

Does it seem like it is on one side? Are you able to shake it up and down and re-create the noise while parked? Is there any noise just by turning the steering wheel back and forth while parked or is it just over bumps? Is it worse turning right or left over a bump or same as going straight over a bump?

Can't seem to duplicate it by shaking anything on the front end or turning back and forth. Seems to happen when hitting bumps no matter if I'm turning or not. I even tried jacking the axle up and dropping the jack down suddenly to try and duplicate it.

 

[Vtur]

The RPM drag link ends have anti-flop inserts, but that's not to say it isn't making the noise. There's not a lot of rotation though.

Mine Synergy also have anti flop joint and it still flop since new.

 

[Arisdocjk]

Has the noise been there since the lift and ats install? Or is it a new noise after the lift has been installed for a while?

 

[Wet Willys]

Has the noise been there since the lift and ats install? Or is it a new noise after the lift has been installed for a while?

Definitely a new noise that has gotten worse over the last few months. I installed the lift about 18 months ago, and the RPM steering kit about a year ago.

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