Front suspension "clunking" issue?

I have more of a "groan" than a clunk. Just sounds like springs on an old mattress. There are speed bumps in my complex and it bugs me everytime I go over them. Not sure if this is the noise you are describing or not...

I hope the solution is something other than replacing the struts, as I have installed the complete Roush suspension kit and still have the clunking issue!

This seems to be an ongong issue as it pops up regularly. Do a search for old threads on it. There is a TSB for strut bearing replacement. Clunking or popping occurs when turning the wheels. Warrantied item.

The upper strut mounts are made from plastic and are a one time use item. If you reuse them you will have the "clunk" problem. Their cheap plastic which can also cause the bearing problem. Either replace with OEM $20 or so a piece or upgrade to J&M's new camber plate for around $250. This information comes from reading numerous threads on suspension, not from personal experience. So take it for what it is worth, but that is how I understand it.

It's a TSB. Go the ford house and get it fixed. I had the same problem and got it fixed under the TSB. I don't remember the exact one but there is a link to all the TSB's at the top of the forum.

the popping noise is a different issuse from the clunking noise, but i do agree that the upper bearing is a cheap design and perhaps replacing this will fix the problem. I have wasted too much time chasing this problem. Ill wait unitl ford comes out with a fix before I do anything else

usually it's the strut mounts or the sway bar endlinks. I have K-Mac camber/caster plates, which eliminate the factory mount. I highly recommend them.

There is a 70 page thread on another site about this. A tsb is coming out for it, soon they say.

CPman said:

I hope the solution is something other than replacing the struts, as I have installed the complete Roush suspension kit and still have the clunking issue!

Click to expand...

CPman - your issue may be related to this safety recall specific to the Roush suspension components, you may want to check this out:

Make : FORD Model : MUSTANG GT Year : 2006
Manufacturer : ROUSH PERFORMANCE PRODUCTS, INC.
NHTSA CAMPAIGN ID Number : 06E071000 Mfr's Report Date : AUG 07, 2006
Component: SUSPENSION:FRONT
Potential Number Of Units Affected : 146
Summary:
CERTAIN AFTERMARKET ROUSH BRANDED FRONT STRUTS AS A STAND ALONE COMPONENT, PART NO. 401297, AND ROUSH BRANDED FRONT STRUTS AS A SUSPENSION KIT, PART NO. 401296, SOLD FOR USE ON 2005 AND 2006 FORD MUSTANG GT VEHICLES. THE FRONT ANTI ROLL BAR ATTACHMENT BRACKET ON THE FRONT STRUT CAN SEPARATE FROM THE STRUT HOUSING DUE TO INCONSISTENT WELDING. THIS COULD RESULT IN A CLUNKING NOISE AND OR POOR HANDLING IN EXTREME OR EMERGENCY MANEUVERS.
Consequence:
IF THE BROKEN BRACKET CONTACTS THE TIRE, SIDEWALL DAMAGE CAN OCCUR, POSSIBLY RESULTING IN A VEHICLE CRASH.
Remedy:
ROUSH WILL NOTIFY OWNERS AND OFFER TO PROVIDE NEW STRUTS FREE OF CHARGE. THE RECALL BEGAN ON SEPTEMBER 18, 2006. OWNERS MAY CONTACT ROUSH AT 734-466-6255. Notes:
THIS RECALL ONLY PERTAINS TO AFTERMARKET ROUSH BRANDED FRONT STRUTS AND SUSPENSION KITS AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON FORD MUSTANG GT VEHICLES MANUFACTURED BY FORD MOTOR COMPANY. CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

Thanks Jenn,
The sway bar attaching brackets look good to me but I will keep an eye on them. I have the same clunking noise with the Roush componants as I've had since day one with the stock suspension. I did notice however when installing the Roush stuff that where the strut goes through the upper bearing, there this a fair bit of play, as in the strut is smaller than the inside of the bearing. I wonder if this is what is making the clunking noise. This was the same with the stock units.

the TSB for "popping" applies to a few hundred vehicles built in 2004. although it's probably related to this problem.

i am one of the lucky few that got rid of the thunking. but unfortunately i did so much at once i cannot tell you wich part fixed it. people have tried just about everything you could possibly imagine. basically, new strut mounts/camber plates and some sort of brace on the a-arms seems to be the most popular bet for the "soon to be issued" TSB. i'm also a fan of tightening the endlinks and using locktite. i can tell you for a fact that installing the Steeda HD upper strut mounts alone did not fix it for me at all. maybe if i'd done that and the g-trac brace it would have. but now i have steeda hd strut mounts, sport springs, pro action struts, X5 ball joints, Gtrac brace, BMR tubular A-arms, and edelbrock strut tower brace and don't thunk. although even after all that stuff my endlinks still thunked til i used loctite [blue]. and yes, the mustangforums thread is exhaustive, heart wrenching, and full of angst.