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Discussion Starter #1
Anybody have this? I get a "knock" when I turn slightly left (not right) and when going slow over bumps.
Anybody with some insight would be appreciated.
 

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I don't think that its the track bar. I would check out your ball joints maybe the ones that you replaced with the new cams need tightening or one was installed backwards. Also check out the ball joint at the bottom of the track bar. Recheck the torque.
This is out of the Icon install manual:


Install new alignment cam: Make sure arrow is pointing toward the front of the truck and the flat end of the cam is aligned with the flat end of the knuckle. Use the old sleeve to tap the new one down onto the taper. Install nut and torque to 69 ft*lb. Install cotter pin.


Jack the axle up 2-3” from full droop. Make sure not to jack the vehicle off of the stands!!! Install the pan rod bar taper end first. Adjust the turnbuckle to length making sure both thread have equal engagement and install in upper end with factory bolt. Torque the upper bolt to 369 ft-lb. Torque the lower to 150 ft-lb.




:icon_ford:
 

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If you have the single damper check it to. If it is loose it could make noise as well. It is gas charged and is always putting pressure in one direction. So if you turn your wheel it could pop do to the opposing force.
 

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I had an after market track bar on my Dodge and it was a worn out heim joint making that noise. It would do it when turning sise to side. Have someone turn the steering wheel back and forth and put your hand on the heim joint.
 

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Discussion Starter #5 (Edited)
It was the heim joint on the trac bar......ICON would not warranty it even though it was less than 2 months old- said it wasn't tightened to their specs----total BS. Their solution was to purchase the new spherical bearing rod end which tells me that they know that their design with the poly bushings are a POS yet they still advertise and sell this. I thought I had read enough about this issue but apparently not. The moral of the story is either don't by ICON as they suck IMHO on warranty issues or pay more for the trac bar with the metal bearing. I have attached a picture of the end that I had to replace- the one on the top is with the poly bushing and the one on the bottom is the new metal bearing one. I suppose it is my fault for not realizing the poly bushing would not be enough for the powerstroke but you would think ICON would know to take it off the market as I can't be the only one who has had this issue.
 

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This is good to know. I got 35k on my icon track bar with the rubber bushing and still going good. But when it goes out I'll be upgrading!:beer:
 

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It was the heim joint on the trac bar......ICON would not warranty it even though it was less than 2 months old- said it wasn't tightened to their specs----total BS. Their solution was to purchase the new spherical bearing rod end which tells me that they know that their design with the poly bushings are a POS yet they still advertise and sell this. I thought I had read enough about this issue but apparently not. The moral of the story is either don't by ICON as they suck IMHO on warranty issues or pay more for the trac bar with the metal bearing. I have attached a picture of the end that I had to replace- the one on the top is with the poly bushing and the one on the bottom is the new metal bearing one. I suppose it is my fault for not realizing the poly bushing would not be enough for the powerstroke but you would think ICON would know to take it off the market as I can't be the only one who has had this issue.[/]

That's weird the bushing doesn't look that bad. I run the hyme join but that bushing still looks in good condition.
 

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Discussion Starter #8
I have attached pictures of the old bushing from the side and top. As you can see the metal sleeve is suspended in the bushing......the bushing isn't worn but it seems as it can't support the bumps/steering without have some compression which I guess gives the knocking sound. My previous picture has the new sleeve surrounded by a metal bearing which I guess can withstand the pounding/weight that these trucks are subjected to. The sad part is that ICON said it was knocking because we didn't tighten it enough (416 ft/lbs)--total BS as it is clearly a lesser design and they know it based on their upgrade suggestion- guess these things are an annuity for them.
After seeing the difference it would make no sense to buy the trac bar with the rubber bushing....its cheaper and now I know why. Just a little more knowledge for those thinking about making the ICON purchase.
 

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Well if that worked for you great. But I do know that there are thousands of those bushing style joints out there. The factory Ford bar use them as well. Before I bought mine I called the factory and I talked to the head engineer about the joint. This was due to talking to a few friends who said it would transfer too much noise in the truck. I was told by the engineer that on the 2008 - 2010 trucks that this was the case. But on the 2011 trucks tested that there was no noise transfer from the bearing style. I was told on the 2011 truck that either style would work great it was just a matter of how much money I wanted to spend. I do think bearing style is a better design personally. That said I still don't know why you were getting a knocking sound when you turn in one direction unless it was possibly loose. Was the sleeve the same width as the opening in the pan bar mount. Or were there washers or spacers missing? Anyway it's good that you got it fixed and the bearing style is much better so good luck.
 

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any update on if the metal bearing worked out for you better than the rubber bushing?

I have the metal one on my truck and its super sloppy and worn out (no clue how long its been on the truck, bought it with it in it) but was just wondering about the longevity. Looks like im going with the 64032 (upgrade end kit) to replace my previously upgraded one but was just seeing how it worked out for you.
 

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I have over 40,000 miles on mine, and it's like the day I put it on.
 

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im glad i investigated before i spent the money on the new end. The bearing / bushing was just fine.

The stock ford bolt was worn down. Was supposed to me 20mmd and it was worn down to about 18. Also the threads were so cooroded that im sure the 406ft lbs (if the PO even torqued it correctly) wouldn't have put the desired squeeze on the bearing allowing it to move around.

new m20x100 bolt, nut, torqued to spec and all my problems are gone. Pretty pleased :D
 

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It was the heim joint on the trac bar......ICON would not warranty it even though it was less than 2 months old- said it wasn't tightened to their specs----total BS. Their solution was to purchase the new spherical bearing rod end which tells me that they know that their design with the poly bushings are a POS yet they still advertise and sell this. I thought I had read enough about this issue but apparently not. The moral of the story is either don't by ICON as they suck IMHO on warranty issues or pay more for the trac bar with the metal bearing. I have attached a picture of the end that I had to replace- the one on the top is with the poly bushing and the one on the bottom is the new metal bearing one. I suppose it is my fault for not realizing the poly bushing would not be enough for the powerstroke but you would think ICON would know to take it off the market as I can't be the only one who has had this issue.
I had similar issue with their poly bushings causing death wobble. Had to buy the new end and it fixed it completely.
 

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OK.. so i read up before purchasing the ICON and deciding to go the extra with the bearing end... replaced the steering damper, track bar and ball joint at the same time.. this was January 2015.. and today it is in the shop repaling the ball joint again, and come to find out, the bearing is shot in the Heim joint... of course they also told me that it probably wasn't torqued to 409.. I guess it is kinda fortunate that they sell just the bearing.. so it is $65 instead of replacing the entire end for $125.. Ford realy stuck it to us with their front end design.. have been driving Powerstorkes for the better part of two decades.. never had this much front end issue. My Dad's 2012 has also worn the factory bar bushing and ball joint out..
 

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yes it's a terrible design

mines still fine at 114,000 miles running 37"s almost the whole time I can't believe that some day I may need to replace a ball joint or bushing

it's complete BS
 
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