Noise coming from front end And Weird gauge problem

CCobraW · Oct 16, 2012

So this past weekend I changed out my front struts, new urethane sway bar bushings and new urethane sway bar end links as well as a front brake job with new pads and rotors. Now I have an odd clunking noise from sounds like right around the wheel when I go around a corner and the road is kinda crappy. When I go over the big speed bumps in the neighborhood it feels super smooth. It's just around corners that it makes this noise. I've gone and rechecked all the bolts and everything is tight and back together like it's supposed to be.

Any clues??

Also when I really get it on it the battery meter in the dash goes almost all the way to the right and just about every warning light in the dash pops on, only for a few seconds until I get off the gas. What the heck is that all about? Is it maybe just a loose connection or I don't know what.

CC'S95GT · Oct 16, 2012

Battery meter- sounds like the internal regulator is going out.Do you have a multi meter. if not remove the alt and have the parts house do a test on it.

what brand of struts. My Koni's had spacers that had to placed in at the right orientation so the strut wouldn't bottom out at full extension. Also did the sway bar bushings fit tight or sloppy?

CCobraW · Oct 16, 2012

I've got a multimeter, where would I test it? On the positive and negative post on the alternator somewhere?

The bushings all fit on the sway bar nice and tight, and I thought I got them thoroughly lubed up with that clear silicone grease or whatever it was that came with them. The struts are the KYB gr2, regular style replacement struts.

CC'S95GT · Oct 17, 2012

You can test the Alt. just by putting the teat leads on the pos. and neg. terminals of the battery.. the alt should be putting out about 14.5vdc+/-2. Now rev the engine slowly and watch the voltmeter. It should fluctuate a couple volts either way but should steady out back at the origional voltage pretty quickly.

When you tightened the sway bar end links, how much did you squash the bushings.

CCobraW · Oct 17, 2012

I got the end links pretty tightened up pretty hard. Are the end links poosibly the prob?

greenscobie86 · Oct 17, 2012

Sounds like the voltage regulator to me too.

Also did you tighten the tops of the struts VERY tight? sometimes they get loose again after settling for a few miles...

CCobraW · Oct 17, 2012

The top nut of the strut is really cranked down. I loosened up the end links just a hair and it quieted it down a bit.

So if it's the voltage regulator, that means new alternator since it's inside it?

greenscobie86 · Oct 17, 2012

If its for the 96 Cobra thats in your Profile, then yes get a new Alt. The VR is located inside it and you cant split the case very easily on the alternator itself, unlike the 2v cars.

One word of advice, dont go for the cheapie rebuilds as they will likely fail. i've gone through 4 no-name rebuilds within 4 months. Same symptoms as you, the shoddy rebuilt alternators couldn't take the high RPMs of the 4v motor I guess.

Do yourself a favor and either buy a brand new OEM MotorCraft alternator or do what I did and scour eBay for a low mileage pulled unit from a Town Car/Grand Marquis/Crown Vic,as there are LOADS of them and they're super cheap since they dont have a "Cobra" attached to them. I picked up a mint MotorCraft Alternator off of a 2001 Linc. Town Car from TX with only 45k miles for $40 shipped. It's been running perfect. If you decide to go the route i went, make sure you only look for the NON-HD/Police package alternators, as the latter units wont fit our Cobras.

Hope this helps you some.

9646gt · Oct 17, 2012

The only time I really had a popping noise like you are having in my front end, it was a bad ball joint that eventually failed and the fender fell on top of the wheel. Luckily I was only driving in a parking lot. Check that out. Maybe one of the lower ball joints was damaged with all the flexing when installing your struts. Not an expert by any means but only speaking from experience. because I think mine was while cornering and really hard bumps. I have the same struts as you and urethane sway bar end links with no issues. All with H&R ss springs.