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Thread: How To: Install Clunk Washers (Pics)

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    How To: Install Clunk Washers (Pics)

    This is a notorious problem on the 97-03 (04 L/heritage) f150's. Ford geniously slotted the rearward lower A-arm mount on the drivers side, and can allow the a-arm to shift and cause a clunk sound usually while turning and/or hitting a bump in most cases. This is not only annoying & embarassing, but can throw the alignment off causing you to eat more tires up front.

    Also, whether you are stock, lowered, etc. these are a good idea. Even if you don't notice a clunk sound, its a good idea to get a set!


    Picture of the culprit....this bolt is in a slotted hole. You can see where it has slipped in the past from the undercoating worn away.




    The yellow circle in the lower right shows the location of this bolt in respect to the rest of the drivers side suspension.




    Photo of the fix. DL's Clunk Washer's. Machined to fit perfectly inside the slot and center the bolt in the hole.



    Purchasing:
    -LFP (http://www.lightningforceperformance...fix-p-565.html)
    -DL (dplynn1@bellsouth.net )
    -Chickenears (http://www.chickenears.com/clunk_washer.htm)

    Install:
    -Jack Truck up so suspension hangs freely
    -Remove Wheel
    -Remove Lower A-arm Bolt (good idea to have a spare jack underneath to support the a-arm incase it happens to shift, although it shouldn't)
    -Install Clunk Washers & Re-install Bolt (They are machined very very pricise, you may have to get the slots lined up, then crank down on the bolt to get them to pop into the slots)
    -Put wheel back & you're done
    -Get the alignment checked!




    Clunk washer installed, & no more worries!



    Last edited by Harley#356; 06-27-2007 at 09:19 PM.

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    were do you get the clunk washers from?

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    World's Fastest Street HD
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    did you read the how-to? lol

    There's 3 sources listed where you can get them from!

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    One day I'll install mine! LOL bought them just haven't installed them yet. Thanks for the How-To with Pics, Josh!

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    thanks i must be blind..lol

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    World's Fastest Street HD
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    lol no problemo!

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    touche 356

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    Thread revival. I'm surprised that even a few years later these haven't come down in price. Depending on what the shipping charges are, these are still $35 for a set of washers - http://www.blueovalchips.com/index.p...t_detail&p=194. My question is...what is the torque for the bolt once we install these?

    I've got F&R swaybars and Bilstein L shocks coming in the mail, so I might as well kill three birds now w/ one stone.
    Last edited by m5james; 07-25-2012 at 02:56 AM.
    2002 HD F150 DSG #01235

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    upper c arm bolts 84-112 ft lb
    lower arm nuts 121-148
    lower ball joint nut 83-112
    upper ball joint nut 57-76
    tie rod end nut 57-76 ft lb
    as per ford service manual

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    So today I finally got around to installing A clunk washer. I was able to get one done on the drivers side, aft hole on the A-arm (sorry for the resolution, was taken from the passenger side). You can see how the tail of the bolt is a 6 sided hex, which helped during the removal process.



    ...but one the passengers side, there was no elongated hole to install the clunk washer. The bolt itself faced a different direction that the drivers side, didn't have a washer under the nut (the drivers side did) and the tail wasn't a hex as the other side was.




    So did I miss something...do both clunk washers go on the drivers side, was there an upgrade somewhere along the way in the frame (but only on one side ) So I'm not sure what to do.

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    the slot is only on the rearward lower A-arm mount on the drivers side.
    2002 DSG HD #09617 NHTOC Truck of the month November 2012
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    I did the most aft hole on the drivers side a-arm, so there is another hole on the forward hole on the drivers side a-arm as well? Why in the world is this only on the drivers side then?

  14. #14
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    I read that Ford did it for ease of setting alignment on the assembly line.

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