front end rattle

[pass1over]

I've had this rattle coming from my front end forever now. I've tried fixing it and never was able to. I live on a limestone/dirt road that's very uneven and this is where I hear it. On flat pavement, it's quiet.

You would think sway bar, right? That's not it.
It's not the control arms, ball joints, or suspension as far as I can tell.

I borrowed a set of chassis ears and the rattling noise seems to be coming from the rack itself. It's not the outer tie rods and it's not the inner's, it's coming from the rack. Tie rod end is quiet and I don't see what could be rattling on the inners at all. They're torqued, not loose, and the adjuster sleeve is tight as well.

What could be rattling inside there? Is is replaceable/fixable or do I need a new rack?

 

[JC SSP]

Very strange...

I did a quick search and steering rack bolts show 74FTlbs and another site had rack mounting bolts at 94 Ftlbs?

Consider checking the torque value... Also loosening and re-tightening the rack and see what happens. Not sure if this requires a loaded front suspension or unsprung?

 

[pass1over]

Forgot to mention, I checked the rack bolts, they're tight. I have also never had the rack out of the car. I have replaced inner and outers, but never unbolted the rack itself.

I could try loosening and re-torqueing them

 

[Forty61]

Nothing in or on the steering shaft that could rattle right? Maybe the sound is just resonating through the rack. Or maybe that mystical 10mm socket that gets lost on every vehicle ever made got loose and is rattling around in the subframe?

 

[pass1over]

I didn't get a chance to check the steering shaft when I was messing with it. That's on the list of things to check out as well next time I have it in the air. I know one of my header primaries is very close to it. I had to clearance it with a BFH and use steeda engine mounts to raise the engine.

Any idea what a good amount of clearance would be for that?

 

[07 Boss]

Forgot to mention, I checked the rack bolts, they're tight. I have also never had the rack out of the car. I have replaced inner and outers, but never unbolted the rack itself.

I could try loosening and re-torqueing them

Did you check the right side of the rack bolts? I believe one side of those bolts are welded. Seen guys trying to remove the rack and can't figure out why the bolts won't loosen. I believe the side you need to wrench on is back side of the rack, not the front. Could be wrong. It's been a while since I was underneath there.

 

[pass1over]

I noticed this awhile ago, Don't know if it has anything to do with the rattle or not.

With car parked, engine off, I can move the steering wheel back and forth slightly and create this sound. It's a little higher pitched in person.

Thought it was my inners going bad, replaced them, noise remains. Does anyone else's car do this?

 

[pass1over]

I'd post a video but it won't let me

 

[DieHarder]

There is a U-joint in the steering shaft that can loosen up over time just due to wear & tear. Mine did. Issue replacing them is finding one is exceedingly difficult these days (if that's the problem). A good alignment shop should be able to pinpoint the problem in fairly short order.

 

[GriffX]

I know from a Mercedes that this adjustable steering wheel clamping mechanism can wear and make noises.

 

[pass1over]

When trying to locate the sound, I was under the car while someone moved the wheel. The sound was coming from the rack. Seemingly inside it, that's why I thought my inner tie rods were going bad.

 

[Blue03Cobra]

There is a U-joint in the steering shaft that can loosen up over time just due to wear & tear. Mine did. Issue replacing them is finding one is exceedingly difficult these days (if that's the problem). A good alignment shop should be able to pinpoint the problem in fairly short order.

Looks like there is an upper and lower section. Which one has the u-joint (or do they both)?

 

[DieHarder]

In my case it was the lower shaft (which is relatively easy to replace). If it's the upper might be lucky to get one out of a junk yard.

 

[Kev555]

It was the lower shaft in mine that gave trouble but instead of the UJ coming apart and getting loose, mine seized with lack of use and age. Rock Auto does both upper and lower at good prices if its a 2012 as listed in your vehicles?

 

[pass1over]

Thank you for all the advice and real world experiences. Hopefully I can get it on the lift this weekend. I have a bunch of maintenance work to do on my girlfriend's 2020 EcoBoost.

For those people whose steering shaft gave out, was a noise apparent when you grabbed it and tried to shake it? I'm wondering how much force is required to make it reproduce the noise.