Bad Front Rancho Shocks

[BenThere]

I have the dealer installed factory 2" lift with Rancho shocks.  For the last several months, I have been hearing a bumping, kinda clunking sound coming from the right front, most noticeable on bad/rough pavement, speed bumps, washboard, those low storm water troughs in rural pavement, that sort of thing.  Was like something loose underneath, loose exhaust, bad bushing, something large not tied down right, something like that.  Drove me crazy! I spent time on rough roads trying to pin-point the source of the noise, holding onto various panels in the truck, the ORV mirrors, etc.  Jacked it up a couple times and spent time banging on everything with my hands and a rubber mallet. Looked at all the suspension, connection points, bushings. Nothing, everything was tight.  Banged on everything else I could imagine making the noise, the bumpers, body panels, the dash, grille, under the hood, in the bed, the camper shell; nothing.  

 

Finally took it into the dealer and took a ride with the service writer until I was sure she heard the same thing I was hearing.  The dealer had some kind of a "chassis ears" device and finally located the noise coming from the left front shock.  Found that the shock had something loose in it; called Rancho and they wanted the shock shipped back to them for "forensic" examination.  They checked the right shock and noticed it was starting to do the same thing. The dealer replaced both front shock assemblies, checked the alignment and road tested; shipped both shocks back to Rancho.   Got the truck back and the noise is gone.   Haven't heard back on what Rancho found.

 

Thought y'all might be interested if you have a Trail Boss, AT4, or the factory lift.  I've used the truck off road quite a bit, here in AZ, Utah canyon country, Nevada, some tough and challenging (close to the trucks capability) roads and trails, but nothing extraordinary, nothing hairier than what I've done with my other trucks over the years with no problems.   Anybody else had a similar issue?  

[SRBOSST1]

I have been waiting for someone to post an issue like this. I bought my custom trail boss back in September everything was great, then came the cold weather. I noticed this "clunk clunk" sound coming from the front end on uneven terrain. I took it to my dealership and a few techs drove it. They told me the same thing it was the right front shock and ordered me a new one. It took well over a month waiting to get the part and during that time the noise stopped! (WTF right?) Now, the weather did get a bit warmer so I figured I would just wait and see if it comes back.

They called me when the shock came in but i told my adviser that there was no more noise and he said "great, then lets not fix what isn't broken". I was fine with that until... the weather got colder and I washed the truck, boom it was back and louder. So... I have been testing it out with the temperature changes and washing, I only hear the noise when its cold and after a wash. I will be taking the truck for a oil change and the recalls here soon and I'll explain to them what is going on. I see your from a much warmer climate and now I may have to go back to the drawing board.    

[Dunn]

2 hours ago, BenThere said:

I have the dealer installed factory 2" lift with Rancho shocks.  For the last several months, I have been hearing a bumping, kinda clunking sound coming from the right front, most noticeable on bad/rough pavement, speed bumps, washboard, those low storm water troughs in rural pavement, that sort of thing.  Was like something loose underneath, loose exhaust, bad bushing, something large not tied down right, something like that.  Drove me crazy! I spent time on rough roads trying to pin-point the source of the noise, holding onto various panels in the truck, the ORV mirrors, etc.  Jacked it up a couple times and spent time banging on everything with my hands and a rubber mallet. Looked at all the suspension, connection points, bushings. Nothing, everything was tight.  Banged on everything else I could imagine making the noise, the bumpers, body panels, the dash, grille, under the hood, in the bed, the camper shell; nothing.  

 

Finally took it into the dealer and took a ride with the service writer until I was sure she heard the same thing I was hearing.  The dealer had some kind of a "chassis ears" device and finally located the noise coming from the left front shock.  Found that the shock had something loose in it; called Rancho and they wanted the shock shipped back to them for "forensic" examination.  They checked the right shock and noticed it was starting to do the same thing. The dealer replaced both front shock assemblies, checked the alignment and road tested; shipped both shocks back to Rancho.   Got the truck back and the noise is gone.   Haven't heard back on what Rancho found.

 

Thought y'all might be interested if you have a Trail Boss, AT4, or the factory lift.  I've used the truck off road quite a bit, here in AZ, Utah canyon country, Nevada, some tough and challenging (close to the trucks capability) roads and trails, but nothing extraordinary, nothing hairier than what I've done with my other trucks over the years with no problems.   Anybody else had a similar issue?  

yeah they aren't really meant for that despite what the marketing is or says

 

if you are gonna use your truck for that purpose would be wise to invest on some real shocks designed for that purpose

[Jav_eee]

Rancho is just another podunk brand now. Nothing special about them.


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[BenThere]

23 hours ago, Shawn Fox said:

I have been waiting for someone to post an issue like this. I bought my custom trail boss back in September everything was great, then came the cold weather. I noticed this "clunk clunk" sound coming from the front end on uneven terrain. I took it to my dealership and a few techs drove it. They told me the same thing it was the right front shock and ordered me a new one. It took well over a month waiting to get the part and during that time the noise stopped! (WTF right?) Now, the weather did get a bit warmer so I figured I would just wait and see if it comes back.

They called me when the shock came in but i told my adviser that there was no more noise and he said "great, then lets not fix what isn't broken". I was fine with that until... the weather got colder and I washed the truck, boom it was back and louder. So... I have been testing it out with the temperature changes and washing, I only hear the noise when its cold and after a wash. I will be taking the truck for a oil change and the recalls here soon and I'll explain to them what is going on. I see your from a much warmer climate and now I may have to go back to the drawing board.    

Yeah, mine was unaffected by weather.  It just kept clunking through it all; but didn't get any cooler than upper thirties here.  

 

Don't let it drive you nuts like I did.  i spent too much time looking for it.  Glad I finally got the dealer to fix it under warranty.  Not worth screwing with it, it's always in your head every time you drive it...... like, "Damn, what is (was) that??  In my new truck???"  Just cant enjoy the truck with that In there (your head).  

[Jaychevy81]

I have a 18 Silverado but I’m getting the same clunking on uneven terrain. Usually when backing in my driveway. It sounds like the front driver side I have the stock ranchos I wonder if it’s the same issue. I tried pushing down on the front but can’t replicate it and it’s not every single time. More like a Ka Klunk.


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[cNate]

I posted on this in the 2020 HD forum. I had this exact thing on my AT4 HD. It started around 2k miles. Seemed to be the back shocks. Checked everything. It stopped doing it around 4K miles. I never got it into the service department because they were too busy the day I went in for a recall, then I went on a long trip.

I was considering just replacing them with aftermarket shocks anyways. If it comes back, then I’ll take them for a ride and show them this post. Thanks for sharing!


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[SRBOSST1]

On 3/22/2020 at 7:16 PM, Jaychevy81 said:

I have a 18 Silverado but I’m getting the same clunking on uneven terrain. Usually when backing in my driveway. It sounds like the front driver side I have the stock ranchos I wonder if it’s the same issue. I tried pushing down on the front but can’t replicate it and it’s not every single time. More like a Ka Klunk.


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Yes its a "Ka Klunk" and to me it doesn't directly sound like the front end more so underneath the middle of the truck. I thought it was a sway bar bushing because that is literally the sound that they make when they wear out. I spent hours looking underneath, knocking things around took the wheels off got in places with a pry bar looking for movement and found nothing. I had my girlfriend sit in the truck as I shook the box from side to side and she said she could hear it. Now I'm going to check the torque on the u bolts and see if the leafs were a bit loose. 

I want to follow Ben There's advice and just have the dealership fix it but I would rather find it myself then take it in, you know? Like I mentioned mine only does it in cold weather after a wash so its very strange. I'm confident it isn't the shocks because its not consistent, its only on uneven terrain go slow. 

Thanks for chimming in guys I hope one of us can figure this out!

[SRBOSST1]

I feel like these threads should be together?

 

 

[Gthompson]

Thanks for sharing, Shawn Fox. 

 

I have a 2020 AT4, I just traded in a 2019 Trail Boss. My AT4 has the same annoying sounds reported. Not necessarily in the rear end. I initially had loose u bolts for the leaf springs, so I could differentiate rear end noise from what this is. They tightened the u bolts and now I'm still left with this clunking (the rear u bolts did fix the feeling that my rear wheels were going to fall off, my truck still has less than 500 miles btw). It sounds as though it's from the center of the vehicle. Went to the original dealer and to a different one. They both point back to "play" in the rear differential. They demonstrated pushing on the rear of the vehicle. I also checked my old truck that was sitting on the lot, a brand new Denali, a used and a new AT4. They all have that axle slap and some rubbing when you push on them. However, my old truck didn't make this slow speed clunk as I drive through my neighborhood or any parking lot and I'm guessing it had the same rear differential. 

 

Honestly, not sure what to do next if the two service departments don't acknowledge it or look into it any further. How much would better shocks cost? And would that void warranty work going forward? I mentioned in my other post, it would be really hard for me to keep this truck with that annoying sound. I haven't listened to it from the outside, but I was pulling in to pick up some takeout and saw a Tundra owner staring at me funny as I clunked into a parking spot. He had to have been able to hear it! Drives me crazy! I ride around with no music playing just to listen to it!

[Jaychevy81]

Yes its a "Ka Klunk" and to me it doesn't directly sound like the front end more so underneath the middle of the truck. I thought it was a sway bar bushing because that is literally the sound that they make when they wear out. I spent hours looking underneath, knocking things around took the wheels off got in places with a pry bar looking for movement and found nothing. I had my girlfriend sit in the truck as I shook the box from side to side and she said she could hear it. Now I'm going to check the torque on the u bolts and see if the leafs were a bit loose. 

I want to follow Ben There's advice and just have the dealership fix it but I would rather find it myself then take it in, you know? Like I mentioned mine only does it in cold weather after a wash so its very strange. I'm confident it isn't the shocks because its not consistent, its only on uneven terrain go slow. 

Thanks for chimming in guys I hope one of us can figure this out!

Ok here is my story on that I did the same thing had the wife drive it in and out of the drive way Ka Klunk. Took it to the dealer after they replaced both axles and diff lol. It turned out to be the rear leaf springs needed grease. So now my driveway has grease spots all over it from greasing these things. But the Klunk now seems more front end I think it’s the shocks but I don’t wanna throw any parts at it until I’m certain. You read all over mixed things on the ranchos I don’t mind them myself but idk what the Klunk is.


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[econometrics]

My Ranchos don't make any of these noises, but I will quickly agree that they are terrible. The boatiness of these shocks is appalling. 

[Jav_eee]

Thanks for sharing, Shawn Fox. 
 
I have a 2020 AT4, I just traded in a 2019 Trail Boss. My AT4 has the same annoying sounds reported. Not necessarily in the rear end. I initially had loose u bolts for the leaf springs, so I could differentiate rear end noise from what this is. They tightened the u bolts and now I'm still left with this clunking (the rear u bolts did fix the feeling that my rear wheels were going to fall off, my truck still has less than 500 miles btw). It sounds as though it's from the center of the vehicle. Went to the original dealer and to a different one. They both point back to "play" in the rear differential. They demonstrated pushing on the rear of the vehicle. I also checked my old truck that was sitting on the lot, a brand new Denali, a used and a new AT4. They all have that axle slap and some rubbing when you push on them. However, my old truck didn't make this slow speed clunk as I drive through my neighborhood or any parking lot and I'm guessing it had the same rear differential. 
 
Honestly, not sure what to do next if the two service departments don't acknowledge it or look into it any further. How much would better shocks cost? And would that void warranty work going forward? I mentioned in my other post, it would be really hard for me to keep this truck with that annoying sound. I haven't listened to it from the outside, but I was pulling in to pick up some takeout and saw a Tundra owner staring at me funny as I clunked into a parking spot. He had to have been able to hear it! Drives me crazy! I ride around with no music playing just to listen to it!

Would different shocks void warranty? Hell no.


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[Gthompson]

17 minutes ago, Jav_eee said:

 

Would different shocks void warranty? Hell no.


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Thanks, Jav_eee. Going to see if the same service manager will drive one of their custom lifted ones around the lot and see if it does the same thing. 

Edited March 25, 2020 by Gthompson

[BenThere]

11 hours ago, Gthompson said:

Thanks for sharing, Shawn Fox. 

 

I have a 2020 AT4, I just traded in a 2019 Trail Boss. My AT4 has the same annoying sounds reported. Not necessarily in the rear end. I initially had loose u bolts for the leaf springs, so I could differentiate rear end noise from what this is. They tightened the u bolts and now I'm still left with this clunking (the rear u bolts did fix the feeling that my rear wheels were going to fall off, my truck still has less than 500 miles btw). It sounds as though it's from the center of the vehicle. Went to the original dealer and to a different one. They both point back to "play" in the rear differential. They demonstrated pushing on the rear of the vehicle. I also checked my old truck that was sitting on the lot, a brand new Denali, a used and a new AT4. They all have that axle slap and some rubbing when you push on them. However, my old truck didn't make this slow speed clunk as I drive through my neighborhood or any parking lot and I'm guessing it had the same rear differential. 

 

Honestly, not sure what to do next if the two service departments don't acknowledge it or look into it any further. How much would better shocks cost? And would that void warranty work going forward? I mentioned in my other post, it would be really hard for me to keep this truck with that annoying sound. I haven't listened to it from the outside, but I was pulling in to pick up some takeout and saw a Tundra owner staring at me funny as I clunked into a parking spot. He had to have been able to hear it! Drives me crazy! I ride around with no music playing just to listen to it!

Man, my truck didn't/doesn't do any of that stuff in the rear dif.  And definitely nothing I can hear in the cab.  Mine all came from the front, and, at least so far, the noise that was driving me absolutely bat-poop crazy is gone.  I was just like you, driving w/o the music, listening to/for the klunking, trying to identify the source of the noise, unable to just enjoy my new truck.  What a delight to have my truck no longer possessed by some evil incubus and Joe Bonamassa back on the Bose.  As for the guy in the Tundra, he was staring at your truck out of pure envy despite possibly hearing the noise .

 

Seriously, though, I'm like you, the way you describe the noise ain't right.  It just ain't.  Our trucks are essentially the same underneath and I don't have that noise (differential).  I wouldn't replace the shocks until you can isolate the noise to the shocks, or you'll still have the same noise driving you nutzoid.  I'd make sure your service writer takes a ride with you and hears the exact same noise you're hearing in your truck, and then drive a new one on the lot and make it perfectly duplicate your truck's demon.  If they can't....... 

 

For your issue as for others' in this thread:  as I mentioned in the OP, the service department, as stated on the invoice, "Install Chassis Ears and isolate noise to front shock assemblies".  Can your dealer perform a similar test, do they have Chassis Ears  https://www.realtoolreviews.com/steelman-wireless-chassis-ears/ , install 'em, and seriously locate the noise?