Carli Track Bar Problem - Ford Powerstroke Diesel Forum
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Old 01-08-2014, 05:03 AM
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Carli Track Bar Problem

I installed a Carli 4.5" Back Country lift with the high mount stabalizer back in August. Today I noticed a knocking noise coming from the front of the truck during turns which have body roll. For instance you hear one pop or bang when you turn from on direction to the next. But if you turn left and then turn left again it will not make the noise the second time. It has to be turns in different directions.
I believe it is coming from the Carli track bar mount. I can grab the bar and twist it to make a knocking noise but I have no idea if that is normal or not. I also noticed on the ball joint side that the ball joint moves up and down when turning the wheels from side to side (Not sure if that is normal). There also seems to be a small amount of slop in the heim joint side but not sure how to tell if the joint is worn or not?
Any help on what to check, tighten, or replace is greatly appreciated!
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Old 01-08-2014, 11:32 AM
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Sounds like the heim joint failed. Carli has good wty supposedly.
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Lrn5000 (01-09-2014)
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Old 01-08-2014, 11:53 AM
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Check the back-side of the track bar and see if there is scuffing from it contacting the cross member. The motor cross members in these trucks are massive and a very rough casting which can cause rubbing depending on how the track bar was installed. If this is the case, shaving the edge of the casting (where the bar contacts) will alleviate the issue. A "popping" is normally the factory ball joint pressed into the axle on the lower mounting position of the track bar. The rotation of the bar allowed by the ball joint on one end and heim joint on the other end should not cause an audible noise unless it allow the bar to contact the crossmember. You can check the ball joint for vertical play to see if it's in good shape as it should be able to rotate, but there should be very little to no vertical movement in the bar.

All this is, of course, assuming the upper mount (heim joint) was torqued to 406ft.lbs. as per factory torque specs/instructions. If the joint was tightened with an impact, an audible click is definitely possible. Wearing out a 7/8" Heat treated, Chromoly Heim joint is pretty difficult to do so that would floor me if it were the case!
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Old 01-09-2014, 06:48 AM
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It was in fact a loose bolt at the upper heim joint mount on the frame. A 3/4" ratchet and 6ft. chunk of pipe allowed me to get another 1/8" turn on the nut but that was enough to stop the noise entirely. Thanks for all the help!
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Old 01-09-2014, 06:52 AM
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Quote:
Originally Posted by Lrn5000 View Post
It was in fact a loose bolt at the upper heim joint mount on the frame. A 3/4" ratchet and 6ft. chunk of pipe allowed me to get another 1/8" turn on the nut but that was enough to stop the noise entirely. Thanks for all the help!
Good to hear. I have my Carli Commuter 2.0 System on the way which has the same track bar.
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