Something loose in front end after Bilstein install? Need help!

[620mac]

Installed 5100's set to 2.8" on my truck the other day, soon as I left with it, there was noticeable clunking sound every time I hit stuff in the road, such as potholes or big cracks. It almost sounds like a broken shock would, but that's of course not what it is, it sounds like something is loose. We thought it could be everything moving into place, but it has not gone away. Truck rides fine, but it has that noise and something is not right. Possible issues from what I've heard could be:

control arms
sway bar linkage
???

What parts exactly are you supposed to remove from the old shock? Do you use the bumpstop provided with the shock or the OEM one? Anyone with any ideas you'd be a huge help. It's on both sides equally, only the front, and it has been digitally aligned 100 miles after installation. I noticed this noise the second I left the shop, before and after alignment.

 

[Doc1609]

Crawl underneath and start looking at all your connections and moving parts. They may not have fastened something down completely and it's moving when you hit bumps. Also have someone drive and stick your head out the window to listen. Have the driver take you to a cul de sac and do a few circles right, then left. This will help you determine if it's a problem related to steering. When I got my jeep lifted, I had the same issue with bumps in the road. Had a buddy take me to a big circle drive and turn both directions. After listening, pinned it to the passenger side. Crawled underneath and noticed a bolt on the sway bar wasn't completely seated. The shop got in a hurry and stripped it out. Instead of retreading it, they used an impact gun to tighten it as far as they could and call it good. I removed it, rethreaded it and put it back in. Fixed all the issues. With all the talk of ball joint failures at this height, may look at them too.

 

[cableguy_hd]

could be that fact that the springs are now compressed and they just sound different when hitting something

 

[Metalizer]

You only were suppose to transfer the bottom spring seat and all the top pieces. You use the bump stop provided with new strut. Also with you setting these all the way up could be causing noise from the ball joint. I installed my set on my 14 a couple weeks ago with no problems, but I set mine at 2.1.

I also tightened my sway bar down after both were finished and truck flat on ground.

 

[NYCruiser]

Check that the ball joint is still seated fully in the upper control arms. Known problem is that the 2.8 setting can push them up and unseat them on '14's.

 

[620mac]

Found it! We re-loosened the sway bar mounts and end links while the truck was in the air, then re-tightened everything, then lowered it back down and re-tightened the nut at the top of the strut.

 

[NYCruiser]

Still keep an eye on those upper ball joints for a while. Some guys report no problems, but others have had them pop.

 

[cableguy_hd]

Found it! We re-loosened the sway bar mounts and end links while the truck was in the air, then re-tightened everything, then lowered it back down and re-tightened the nut at the top of the strut.

what do you use to tighten the strut nut when its in place?