I'm running out of ideas here... I have a '93 F-150, extended cab, 2WD,
300/E4OD that I bought used with about 120K miles on it. It currently has about 140K. When I bought it I knew that it had a few issues that needed to be addressed, most notably tires out of balance and bad shocks, but overall it seemed to be in good shape. To date, I have replaced the shocks (myself,) had new tires installed (Michelin LTX AT/2- I know they're a little aggressive for a 2WD truck, but they were on sale when I bought them, and I drive the truck so seldom I figured that a little NVH was not going to be objectionable, and I wanted to make sure I could get around in winter) and also had a full brake job done on the truck (a note from my last safety inspection said that the rear shoes were almost at the wear limit, so I replaced everything, because it pulled a little and the front rotors were warped) including all hardware and hoses, and had the front wheel bearings replaced (that needed to be done at purchase as well.) Probably not related, but I also have replaced or had replaced all fluids in the truck as PM save for the power steering (and if I don't set this thing on fire in disgust, I will probably do it again at 150K miles.)
Even after the brake job, I still have some NVH from the front end. There's a loud clicking/clacking noise coming from somewhere that is wheel speed related; it sounds like a much louder version of a stone being caught in a tire tread, or a stone loose inside a hubcap. It becomes much louder when you go around a corner, and you can feel a vibration as well - not through the wheel, but in the seat and through the floor. After the brake job, I took the truck back to the shop that did the work and they diagnosed the problem as a bad U-joint. I told them to go ahead and replace all three, as I had noticed that there was some backlash in the driveshaft but hadn't addressed it yet. If anything the vibration was worse after that. I had the driveshaft straightened and balanced, and the problem remained, but it was approximately the same as it was before U-joint replacement. In disgust, I took the truck to another shop and the guy there completely disassembled the front brakes from the spindles out, reassembled, claimed he didn't find anything wrong but that he felt the truck drove much better afterwards - he was right. Unfortunately, the problem has reappeared and I've put less than 1000 miles on it since then.
My best theory at this time is it's a combination of slight play in the wheel bearings combined with pads not fitting tightly in the calipers. If it matters the pads that I bought were Raybestos ceramics, part no. ATD375C. But I'd really like to have this resolved because the noise is embarrassing (it's loud enough that I'm sure people driving next to me can hear it) and it worries me that I might be misdiagnosing and that there's a serious problem that I'm ignoring/writing off to nothing important and I don't want to have a serious failure on the road.
Any ideas...?
Completely unrelated, the battery was dead this morning which pisses me off, as I have had both the alternator and battery replaced fairly recently, and also when I got the truck I went through and cleaned all of the accessable connections and grounds and slathered them with silicone grease as PM, because I've always thought that the charging system on this truck was kind of tenuous from the way the voltmeter drops at idle with any accessories or lights on (it still does it by the way, but I've been told by everyone that looks at it that it's perfectly normal)
I'm about to drop the truck off at yet another shop to let them have a stab at it as I no longer have a good work space of my own, but figured I'd throw this out there to see if anyone has any ideas. (I also don't have a very high opinion of most mechanics; it took my buying a set of "known good" wheels and tires for my old Porsche and swapping them one by one in my driveway before I diagnosed a NVH problem in that car that
5 different shops, including one owned by a guy with a nationally syndicated radio and TV show, could not even detect - and yet both I and my ex-fiance's father - the only other mechanically inclined person to ever drive the car while I had it - both considered it blatantly obvious. If anyone knows of a GOOD shop in the Dulles Airport area, I would certainly like to have your recommendations.)nate