On my 05 Z71 when I hit potholes or rough road the front end clunks. Sounds like it's falling apart. It has to be sharp drop edges in the road. Normal smooth dips are fine.

I have on 3-4000 miles on the Bilstein HD's and pretty sure all is good there.

Dealer said it was the intermediate shaft and replaced it. Well, it's still there.

Any idea what to look at?

 

Hey there tsduke,

How you doing today.

I hate to say it, but I've got an 04- 2500HD 4X4 with Rancho 9000s, and it just doesn't respond well to hard off-road use. These torsion-bar IFSs just aren't made to hit the dirt aggressively.

Fortunately in my case, I only do what off-roading I have to, to get by.

 

I've thought that too, but it's worse than it used to be. I'm not even referring to offroading, just rough town road...and our city has plenty of them.

 

bushings are the first thought in my mind and tie-rods are 2nd, jack it up and wiggle the tires see if there is any play, if there is then see where it comes from, grab and shake all the components under there, u may discover where it is coming from, dealers just want to throw parts at things like that rather than do an actual inspection of the suspension

 

I had this problem before awhile ago on another truck. check to make sure the shocks are bolted tight. I could not find the noise for a long time. come to find out one of the front shock bolts was loose and made a clunk noise when I hit bumps just like what is happing to you.

 

While you're under there looking at everything else, you will want to have a look at your front stabilizer links; I'm on my third set now at 90K, the other day I went to check out my front end, and the driver side link was totally gone!

Seems like the driver side just keeps tearing up links, for some reason.

 

^^^^ i have seen that many times

 

I would basicly just check a few things for free play
check your sway bar bushings,ball joints, tie rod, bushings in the ifs

I unfortuantly have to drive 100k of dirt road everyweek to get out of camp, and feel like my truck is just going to collapse on me,