2022 Ford Ranger Steering Clunk

[KWR]

I have been lurking on the forums for a little bit now but this will be my first post. My truck is a 2022 Ford Ranger Sport 4x4 with 13130 Miles on the clock. I am getting a clunk that cannot be heard but can be felt in the steering wheel usually when turning. It only happens after I have been driving for 10+ minutes and it has to be warm outside. The dealership has already replaced the lower coupling because it was binding when I would dry steer but that has been taken care of. When I took it back because it was still clunking they said they could not reproduce it. With such low miles there should not be any looseness and clunking felt in the steering wheel. When I look I cannot see or feel anything that is loose. Has anyone else had this problem and fixed it? Here is another thread that had similar issue but no one had any answers:

https://www.ranger5g.com/forum/thre...-intermittently-through-steering-wheel.21006/

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[rang19ca]

I'm not sure what it might be. Can you have someone operate the steering while you listen for it outside near the wheel?

 

[airline tech]

Its going to take a extra helper to possibly isolate the (Thump - Clunk)

So I assume this was already replaced and they found this to be binding.

The upper shaft (cab side of firewall) also has a coupler union like this, so when you have it in the condition for it to (Thump), place your hand on the shaft while turning the steering wheel and see if you can feel it - most likely (YES)

With you noting that it appears after 10 minutes of driving, directs my attention to the engine bay side of the steering.
So steering gear (EPAS) or steering knuckle, tie rods, ball joints, stab bar links etc, binding slightly when they are heated up (expanding) mainly from braking action - heating up the knuckle.

So when hot (if it does it while stationary) - place your hand on various points that move, I would focus on the stab bar end links and feel for the (Thump) that you are feeling in the steering wheel.
My hunch is that with hands on and possibly a stethoscope you will be able to isolate it down.

Plus - also note Is Lane Assist (On or Off) when its (Thumping)?
Turning Left or Right or does it do it on both turns?
Feel it on (Turn) or (Wheel Return to center)?

 

[KWR]

Its going to take a extra helper to possibly isolate the (Thump - Clunk)

So I assume this was already replaced and they found this to be binding.

The upper shaft (cab side of firewall) also has a coupler union like this, so when you have it in the condition for it to (Thump), place your hand on the shaft while turning the steering wheel and see if you can feel it - most likely (YES)

With you noting that it appears after 10 minutes of driving, directs my attention to the engine bay side of the steering.
So steering gear (EPAS) or steering knuckle, tie rods, ball joints, stab bar links etc, binding slightly when they are heated up (expanding) mainly from braking action - heating up the knuckle.

So when hot (if it does it while stationary) - place your hand on various points that move, I would focus on the stab bar end links and feel for the (Thump) that you are feeling in the steering wheel.
My hunch is that with hands on and possibly a stethoscope you will be able to isolate it down.

Plus - also note Is Lane Assist (On or Off) when its (Thumping)?
Turning Left or Right or does it do it on both turns?
Feel it on (Turn) or (Wheel Return to center)?

That is exactly the part they replaced. I got to looking at it last night and it is still clunking somewhere in the steering shaft. Everything else in the steering is still tight. I will attach a video of what found. I cannot tell if it is coming from the new part they installed or if it is the EPAS. But you can clearly hear the thump or clunk. I am going to send this to my service advisor and see what she says. I will also add that no matter if its hot or cold there is more vibration in the wheel than there should be. It is definitely not a tire issue either because it is not a shake but more vibration that can be felt.

 

[ScarzRanger21]

I have been lurking on the forums for a little bit now but this will be my first post. My truck is a 2022 Ford Ranger Sport 4x4 with 13130 Miles on the clock. I am getting a clunk that cannot be heard but can be felt in the steering wheel usually when turning. It only happens after I have been driving for 10+ minutes and it has to be warm outside. The dealership has already replaced the lower coupling because it was binding when I would dry steer but that has been taken care of. When I took it back because it was still clunking they said they could not reproduce it. With such low miles there should not be any looseness and clunking felt in the steering wheel. When I look I cannot see or feel anything that is loose. Has anyone else had this problem and fixed it? Here is another thread that had similar issue but no one had any answers:

https://www.ranger5g.com/forum/thre...-intermittently-through-steering-wheel.21006/

Have the same issue with mine… Been doing it for like 2 years and still can’t find the issue. I’ve taken it to multiple shops and the entire front end has been taken apart 3 times. Nobody can find where the noise is coming from. At this point, I’ve had multiple mechanics tell me that everything is structurally sound and there aren’t any signs of worn, broken, or binding parts. I’ve learned to just deal with it. It’s “one of those things” man.

 

[KWR]

Have the same issue with mine… Been doing it for like 2 years and still can’t find the issue. I’ve taken it to multiple shops and the entire front end has been taken apart 3 times. Nobody can find where the noise is coming from. At this point, I’ve had multiple mechanics tell me that everything is structurally sound and there aren’t any signs of worn, broken, or binding parts. I’ve learned to just deal with it. It’s “one of those things” man.

Is yours a noise or can you just feel the clicking/ clunk in the steering wheel? I cannot actually hear any noise. Mine is just felt through the steering wheel when it is hot outside.

 

[ScarzRanger21]

Is yours a noise or can you just feel the clicking/ clunk in the steering wheel? I cannot actually hear any noise. Mine is just felt through the steering wheel when it is hot outside.

Both. My wife can hear it too when she’s riding with me so I know it’s not just me being paranoid. Seems to happen more when I hit speed bumps or when I’m backing up and turn the wheel. Even sitting still, when I turn the wheel I can hear and feel a popping/knocking sound. It doesn’t happen when driving but I think it’s because the road noise and vibration masks it.

I’ve replaced ball joints, tie rod ends, sway bar links, brake calipers, and radiator mount hardware but it’s never gone away. Got tired of throwing money at it so I’ve learned to live with it. After multiple mechanics telling me nothing is wrong, I’ve just accepted it.

I saw another thread/post on here where someone said it was the knuckle joint in the steering column. When I get under the hood and shake mine around, there’s a little play but I think that’s normal. Every other vehicle I’ve had has been the same. I make sure to check mine every other oil change and apply grease as I feel is necessary. Idk if that’s really preventing or helping anything but it makes me feel better at least lol. I’ve also heard to check the body mounts and rear leaf spring connections. Apparently some people have found loose nuts and bolts from the factory.

The only other thing I can think to check would be your lug nuts and axle nuts. Make sure they’re torqued to spec. As long as everything is torqued correctly and you don’t see any signs of worn out parts, I wouldn’t worry too much about.

Also, are you 100% sure it’s not just the tires popping on the pavement? A way to check this would be to jack the front end up so the tires are off the ground. Turn the wheel back and forth to see if you still hear/feel the same thing. Could also just be that the coils are compressing and stretching under load. When it gets hot or cold, things shrink and expand. Not unusual to hear noises when the weather changes.

 

[KWR]

Both. My wife can hear it too when she’s riding with me so I know it’s not just me being paranoid. Seems to happen more when I hit speed bumps or when I’m backing up and turn the wheel. Even sitting still, when I turn the wheel I can hear and feel a popping/knocking sound. It doesn’t happen when driving but I think it’s because the road noise and vibration masks it.

I’ve replaced ball joints, tie rod ends, sway bar links, brake calipers, and radiator mount hardware but it’s never gone away. Got tired of throwing money at it so I’ve learned to live with it. After multiple mechanics telling me nothing is wrong, I’ve just accepted it.

I saw another thread/post on here where someone said it was the knuckle joint in the steering column. When I get under the hood and shake mine around, there’s a little play but I think that’s normal. Every other vehicle I’ve had has been the same. I make sure to check mine every other oil change and apply grease as I feel is necessary. Idk if that’s really preventing or helping anything but it makes me feel better at least lol. I’ve also heard to check the body mounts and rear leaf spring connections. Apparently some people have found loose nuts and bolts from the factory.

The only other thing I can think to check would be your lug nuts and axle nuts. Make sure they’re torqued to spec. As long as everything is torqued correctly and you don’t see any signs of worn out parts, I wouldn’t worry too much about.

Also, are you 100% sure it’s not just the tires popping on the pavement? A way to check this would be to jack the front end up so the tires are off the ground. Turn the wheel back and forth to see if you still hear/feel the same thing. Could also just be that the coils are compressing and stretching under load. When it gets hot or cold, things shrink and expand. Not unusual to hear noises when the weather changes.

Before the dealer replaced the lower coupling (part with the u-joints) I was getting the clunk when backing up and dry turning in park. Now that it has been replaced it only happens when driving and usually turning especially into a parking lot when it is hot and the truck has driven a few miles. So that lower coupling fixed the binding that was going on which it sounds like what you have. Have you tried replacing that lower coupling?

 

[airline tech]

The main question is what caused the (Lower Shaft) to wear to the point that it started binding.

The (Upper Shaft) also has a (U-Joint) but the shaft is fixed at the firewall.

So pinpointing down to something that is heated up from driving points to something on the engine bay side.
I am just throwing out the possibility that with steering parts expanding and increasing tension on the EPAS - the weak point could be the (Lower Shaft - U-Joint)

I think I would check the EPAS Gear attach bolts to ensure they are tight, my THOUGHT is that those attach bolts may not be secure, when cold (less resistance) and they may not allow movement of the EPAS Gear, but when hot (more resistance) may allow the EPAS Gear to move slightly, this is the clunk / thump you are feeling and a possibly reason for the (Lower Shaft) to wear out.

Torque Spec for the EPAS Gear Bolts = 122 Ft Lbs

Again this is something to check along with Steering Knuckle Etc

 

[KWR]

The main question is what caused the (Lower Shaft) to wear to the point that it started binding.

The (Upper Shaft) also has a (U-Joint) but the shaft is fixed at the firewall.

So pinpointing down to something that is heated up from driving points to something on the engine bay side.
I am just throwing out the possibility that with steering parts expanding and increasing tension on the EPAS - the weak point could be the (Lower Shaft - U-Joint)

I think I would check the EPAS Gear attach bolts to ensure they are tight, my THOUGHT is that those attach bolts may not be secure, when cold (less resistance) and they may not allow movement of the EPAS Gear, but when hot (more resistance) may allow the EPAS Gear to move slightly, this is the clunk / thump you are feeling and a possibly reason for the (Lower Shaft) to wear out.

Torque Spec for the EPAS Gear Bolts = 122 Ft Lbs

Again this is something to check along with Steering Knuckle Etc

Is the EPAS gear bolt the long bolt that bolts the steering rack to the frame?

 

[airline tech]

Yes - EPAS - Electric Power Assisted Steering - Gear is its official name.
It incorporates the electric portion of it as
PSCM - Power Steering Control Module adjusts assist - speed dependent.

 

[KWR]

Yes - EPAS - Electric Power Assisted Steering - Gear is its official name.
It incorporates the electric portion of it as
PSCM - Power Steering Control Module adjusts assist - speed dependent.

I just checked and both are properly torqued so I don't think that is the issue.

 

[Dereku]

Steering wheel bolt loose? Does it do it at all steering wheel positions? Like fully up or down.

have you ever greased all your ball joints? They have needles for ones without zerks.

 

[ScarzRanger21]

Before the dealer replaced the lower coupling (part with the u-joints) I was getting the clunk when backing up and dry turning in park. Now that it has been replaced it only happens when driving and usually turning especially into a parking lot when it is hot and the truck has driven a few miles. So that lower coupling fixed the binding that was going on which it sounds like what you have. Have you tried replacing that lower coupling?

I haven’t but that was after multiple mechanics took everything apart and told me nothing was wrong. Maybe one of these days when I get some time I’ll consider replacing it.

 

[KWR]

Steering wheel bolt loose? Does it do it at all steering wheel positions? Like fully up or down.

have you ever greased all your ball joints? They have needles for ones without zerks.

I do not believe the steering wheel is loose. It will do it no matter the position the steering wheel is in. I have not tried to grease any ball joints but I did grease the slip part of the steering shaft with no luck.

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