I have a 96 2500 that has developed rattle on both sides of the front end.
I inspected it and found that the lower ball joints were pretty badly worn so I replaced them, the rattle is still there.
Just wondering if this is a common problem and if anyone knows what the problem might be. I've also check and replaced the bearings as well.

Some may notice that I posted this same question in the 911 help forum.
OOPS I didn't realize where I was posting at the time so I'm posting here
as well/instead.

 

Is it more of a rattle when the wheels are turning, or more when the suspension is articulating (I know, big word).


phox

 

More when the suspension is articulating.
I've replaced the shocks as well as the balljoints.

 

Check the lower shock bolts first, mine loosened up not too long after replacing them on my previous truck. If they're nice and tight, you might have Rancho shocks with too-small bushings at the bottom, or you might need new bolts as some people have found and reported in other threads. Other possibilities would be track bar going out, although I can't remember anyone talking about noise from that, just scary front-end bouncing.

 

I kept having problems with rattling on my front end after replacing my shocks. There was another thread with a similar issue about a month ago where 5 members all stated that the shocks needed to be (re)tightened. I was able to give each lower bolt another 1/4 to 1/2 turn, and my rattle went away. Now I can concentrate on the loose steering .
Franklin

 

my 96 2500 rattled pretty loud when the U-joints on the outer axles were shot so you might want to check those.

 

Mine is not 4WD.

 

they are hard to check, but the sway bar links go bad also. mine was bad, replaced it and the noises went away. the thing is loaded all the time tho, so you cant just shake it, you have to see if you can move it with a pry bar or something.

 

hmmm I'll have to check that out.

 

My money is on the lower shock bolts. They need to be SUPER tight.

 

Yep, I thought mine were tight when I installed the Ranchos. I had to go back and hit 'em again after the first test drive!

Rusty

 

My lower bolts were snug, and no rattle with my old shocks(originals, I didnt buy it new) I removed the bolts with a 1/2" ratchet, no problem. I put the new shocks on, and tightened them with the same ratchet. I put all I could muster on them. The rattled like a rock in a bucket. I figured they had given me the wrong shocks. I compared the two, old to new, and the new ones do not have a true seamless bushing(rolled flat stock) and it is a little bigger than the originals bushing. I went back and put a 1/2" air impact on it and stopped the rattle.

 

I add a similar problem and I found out that the stud for the wheel where badly wear where the rotor is sitting causing the rotor to be very loose I change all the stud and my rattle stop.

Buzzman

 

When I replaced front shocks. With aname brand shockI found that the hole thru the bottom mount was larger than the original and this meant that the monting was requiring the tension was on the sides of the mount and not on the bolt. This has been a noise problem requiring the lower mount bolt to have to be retightend a couple of times to remove the "rattle" in My 97 2500.Hope this might help.

 

I had Monroe shocks from Sears installed on the front. About a week or so after, I started to hear a rattle noise, brought it back to Sears. They said Monroe shocks had smaller roller pins than the stocks, so they added some shims and no more noise.

It was funny as soon has I told them what the problem was and what kind of truck. The mechanic said I know what it is, pull her in.

Monroe is aware of the problem and has sent the shims out to all Sears Automotive stores.