Crunching/popping noise in front end?!

[ScarzRanger21]

Recently started hearing an odd noise in the front end that I can only describe as a "crunching/popping" noise. I've spent HOURS under the truck trying to figure out where this noise is coming from with no luck. It's been to two different shops over the last few moths and they couldn't find anything wrong. Everything is torqued correctly, alignment is fine, bearings are fine, bushings are good... Everyone can hear it (I know I'm not going crazy) but nobody can locate the source of the noise. It's driving me nuts!!! It only happens at low speeds like when I'm rolling down my gravel driveway, driving through parking lots, and hit bumps. It's especially noticeable when I'm turning the wheel and backing into a parking spot. Also does it when pressing the gas from a stop. It's not a consistent ticking noise like a worn CV axle would normally make. Almost sounds like rubber squeaking, it's definitely not metal on metal grinding, but it's a deep popping/crunching noise. Hard to explain without actually hearing it yourself. No feedback in the steering wheel, just something I can hear in the front end.

The truck just hit 50k miles a couple weeks ago so I can't imagine anything is worn out yet like bearings, CV axles, etc... This has been confirmed by two different mechanics. I have a Rough Country 3.5" lift. I know RC isn't the most high end brand but I don't do any serious offroading with this truck so don't judge me too hard! Lol Has anyone else experienced this with their Ranger? Please tell me I'm not the only one! 2021 Ranger XLT 4x4

Edit to original post: After sitting on hold for almost 2 hours, finally got a hold of someone at RC. They said less than 1% of their customers have had any negative comments about the ball joints that come on this lift kit. They can’t think of any reason why after 6-8k miles they would be failing. They confirmed that Moog k6540 ball joints will fit their control arms. Gonna give them a shot and see what happens. Hopefully this finally solves my issue. We’ll see…

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[Dereku]

Disconnect sway bar and try again. Could be end links or the sway bar bushings. Tricky to diagnose, just remove from equation.

 

[Dereku]

Upper ball joints and wheel bearing have my vote tho

 

[airline tech]

Disconnect sway bar and try again. Could be end links or the sway bar bushings. Tricky to diagnose, just remove from equation.

That would be my guess as well as a possible and the trigger for the thought is (Turning) Sway Bar End Links (Pivoting)
You could try - getting the steering in the position you hear the noise and then (Rock) the front suspension (side to side) - (up and down) to see if you can duplicate the noise.

 

[Burnt Money]

Something to try is make a set of grease plates. Well that’s what I know them as lol. Get sheet metal, lexan or something like that. Cut 4 squares say 12in x 12in. Take 2 of the pieces and smear grease in between them and put them together. Then do the same with the other pieces. Put 1 set in front of each front tire. Drive on them to where the tire is centered on them. Now you can turn the wheel from lock to lock easily without having the friction of the tire on the ground. You can also bounce the front end and not have the tires contacting the ground. It may help to get under the truck with someone else turn the wheel. This trick may help you or it may not. Figured it was super cheap or even free to try.

 

[ScarzRanger21]

Disconnect sway bar and try again. Could be end links or the sway bar bushings. Tricky to diagnose, just remove from equation.

I’ll definitely try that this weekend.

 

[ScarzRanger21]

That would be my guess as well as a possible and the trigger for the thought is (Turning) Sway Bar End Links (Pivoting)
You could try - getting the steering in the position you hear the noise and then (Rock) the front suspension (side to side) - (up and down) to see if you can duplicate the noise.

Tried that. Had my buddy bouncing the truck while I was laying under it. The odd thing is that I can’t really hear anything under the truck. It only seems to happen when it’s moving.

 

[ScarzRanger21]

Upper ball joints and wheel bearing have my vote tho

Might be bearings? The ball joints are pretty new. The first set I got with the lift kit were shot after 8k miles so I had RC country replace them under warranty. This newer set only has 6k miles or so on them and the boots are already torn.
I’m not going to keep replacing ball joints every 6 months so I’m looking for an upgrade from whatever RC uses. They’re clearly crap and don’t last.

 

[Bob902]

Disconnect sway bar and try again. Could be end links or the sway bar bushings. Tricky to diagnose, just remove from equation.

This.


I would start with the sway bar end links. I had this issue after installing my Eibachs. You need an 18mm offset wrench to get it tight.

 

[cmhmh]

I had my sway bar end link snap and I had, I presume, this same sound. Removed the entire sway bar and it immediately stopped.

 

[Dereku]

Might be bearings? The ball joints are pretty new. The first set I got with the lift kit were shot after 8k miles so I had RC country replace them under warranty. This newer set only has 6k miles or so on them and the boots are already torn.
I’m not going to keep replacing ball joints every 6 months so I’m looking for an upgrade from whatever RC uses. They’re clearly crap and don’t last.

Based on that, your ball joints are shot. No question about it.

 

[ScarzRanger21]

Based on that, your ball joints are shot. No question about it.

Where can I find ball joints that will fit the aftermarket control arms that came with the lift? They’re a different size than stock but RC really doesn’t have much info about sizing on their website. I called and asked one of their reps so I can replace them with something better. The response I got was “I don’t know, I’ll get back you…” and they never did.

They offered to send me another new set under warranty, again, but I don’t want to have to keep doing this every 6k miles.

 

[veedubtuner]

I vote maybe opossums in the undercarriage somewhere eating

On a serious note, hope you find the noise and rectify it.

 

[ScarzRanger21]

I vote maybe opossums in the undercarriage somewhere eating

On a serious note, hope you find the noise and rectify it.

No but definitely had a few rats get in there… I had to put a wire mesh screen over my air intake because they kept making nests in the air filter housing. Country life problems! Lol

 

[airline tech]

This will take some research as IDK if RC uses the same as BDS - as another member had similar issues with Ball-Joints.
I agree more than likely if the boot is torn - then the grease is gone, and it is most likely to be dry.
Now if this the actual noise - Possible

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