jburkitt Posted October 11, 2016 Share Posted October 11, 2016 Hey guys, 08 ford fusion 5-speed. In the last year, i have replaced both front struts (twice), both sway bar links (twice) and the outer tie rods. I also replaced the strut mounts with brand new units both times. I put monroe sensa tracs on the first time and started to get a "clunking" noise, i took it to get an inspection where i was told everything is tight and that it is the nature of the Monroe struts. I did some research and found that KYB struts are OEM so after some time and gradual increase to the "clunking" noise, i installed KYB struts. Both times i replaced the sway bar links for good measure. Now that i have the KYB struts it was nice and quiet for almost 2 weeks, now i get a "rattle" noise without a lot of suspension travel, just a small bumb at low speed all the way up to faster speeds, same "rattle" I took it again this morning for an inspection and was told that everything is tight. I have physically checked every bolt, bushing and component in the front end and am now at a loss... Any and all help would be substantially appreciated.Thanks 0 Quote Link to comment Share on other sites More sharing options...
jburkitt Posted October 12, 2016 Author Share Posted October 12, 2016 *update*I rechecked all the nuts, bolts and various fittings after work last night. Turns out the nuts on the 3 bolts that hold the upper strut mount in place worked themselves loose. Problem solved... For now 0 Quote Link to comment Share on other sites More sharing options...
jlong Posted January 6, 2017 Share Posted January 6, 2017 (edited) Rather than start a new discussion I'm going to use yours. I have this rattle noise at slow speeds and it sounds like what you are describing. I did suspect the same 3 nuts you mention but they are hand tight. I might have to check it with a wrench. I also suspected sway bar end links or sway bar bushings. It really sounds like the sound a bar would make if it were loose in a rubber housing, if that makes sense. Kind of like a clunking noise. If the 3 bolts don't fix it I'm going to check the sway bar. I did change the upper and lower control arms recently along with the shock and mount. I guess it could be the upper control arm. I'm going to have to go over every bolt again I guess. How hard is it to change the sway bar bushings on a 2010 sport? Edited January 6, 2017 by jlong 0 Quote Link to comment Share on other sites More sharing options...
WWWPerfA_ZN0W Posted January 6, 2017 Share Posted January 6, 2017 I have a feeling you are not going to like the answer, but here goes ... 2012 Fusion Front Stabilizer Bar Bushing & Link.pdf 1 Quote Link to comment Share on other sites More sharing options...
jlong Posted January 7, 2017 Share Posted January 7, 2017 No effing way. Let's hope it isn't the bushings. Damn it I wish I would have thought about them while my engine was out! 1 Quote Link to comment Share on other sites More sharing options...
jlong Posted January 7, 2017 Share Posted January 7, 2017 So I had to go to work this morning and it was 19° outside. Freaking cold for Katy (suburb west of Houston). The rattle was extra bad. When I got home I checked the 3 nuts on each side but they were tight. I got maybe 1/8th turn on each one on both sides. I also tightened the nut in the top of the shock. I remember when I reassembled the shock and mount the nut didn't go on that far, but everything was snug. There isn't any thread showing. I tried tightening it more and almost stripped the nut because of the angle the wrench was on it. I really think there should be 2 regular nuts instead of the lock nut so you could get it tighter. Oh well. The noise is gone! It must have been the same thing as the OP. So that's the end of that for now I guess. Hope this helps someone else. 1 Quote Link to comment Share on other sites More sharing options...
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