Crunching/popping noise in front end?!

[ScarzRanger21]

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

(1) BDS Upper Arm Help Please….. | 2019+ Ford Ranger and Raptor Forum (5th Generation) - Ranger5G.com

According to Moog, their k6540 ball joint will fit the RC control arms… Gonna replace them and see what happens.

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[WOADKIL]

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.

I've used cardboard in similar manner..

 

[ScarzRanger21]

Finally made some progress… After the mechanic bailed on me earlier this week, I decided to swap the ball joints myself. Pressed them out only to realize the ones I had ordered (confirmed by RC and Mooog) didn’t fit!!! After losing my freaking mind, I made some calls to different parts suppliers to finally come to a realization… The lift kit that was originally installed came with the wrong control arms. The arms in the lift kit that RC supplied are meant for aluminum steering knuckles, not steel. For the last two years I’ve been driving with the wrong control arms, which is why I keep having ball joint failures! (Sidenote: You’d think the shop that installed the lift kit, who specializes in offroad/aftermarket suspension parts would’ve caught this, but I guess I’m past that now.)

After spending hundreds in shop inspection fees, incorrect information from suppliers, ordering the wrong parts, and playing “guess what fits…” the new CORRECT control arms arrived yesterday. Installed this morning and took the truck for a test drive. Clunking noise is finally gone and the truck rides much better!

What I learned? RC sucks and their customer service reps clearly don’t have a clue what they’re doing. Didn’t mention this earlier but they also sent the wrong wheels for my truck, after talking to their rep on the phone and “confirming” they would fit… In hindsight, I should’ve spent the money on a better brand instead of trying to be cheap. Ended up costing me more in the end. You get what you pay for. ?‍

 

[airline tech]

Awesome - a final resolution, it has been mentioned on here about Ford changing the Knuckles (Mid Production) 2020 from Aluminum to Steel.
I actually forgot about that and never crossed my mind for this thread, now you have mentioned it I think others have had similar issues for fitment and correct parts ordering.

I will say - GOOD CATCH

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