Pop from front driver suspension . Please HELP

[Broncenstien]

Hey there,
I’m at my wits end. I’ve got a 2021 outer banks non sas. 6 months ago I started getting a metallic popping noise when I turn to the left and/or go over bumps… only at slow (sub 10 mph) speed. Sometimes it happens for the entire drive. Sometimes not at all. The steering is tight and maintains alignment. thats the problem. Here are the solutions I have tried…
Replaced the cv
Replaced the hub
Upgraded the tie rods
Checked the steering rack for any damage to the rack and pinion.
Added bushings to the rack and pinion (for less play)
Upgraded the upper control arm & ball joint
Got an alignment (mechanic found no issues and couldn’t hear the sound during the test drives)
Flushed the differential fluid and checked theoil for metal shavings with a magnet.

So now I reach out to the bronco community for any ideas?

Any help would be greatly appreciated!

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[Brian_B]

There is a TSB about the FDU mount being cracked/broken and it could possibly make that noise.

You already looked at everything I would have checked too.

 

[VirginiaHeritage]

Likely totally unrelated, but the Subaru started doing something similar at 50k and it’s caused by the steering rack . The TSB for it calls for replacing a tensioner spring for the preload between the toothed rack and the mating pinion gear. Basically these parts would separate and bounce back together with a pop over bumps and rough roads. It became a cacophony of pops going down our gravel road. Subaru claims it doesn’t cause damage to the rack and is just a nuisance noise. No idea if this could be a possibility on the Bronco.

 

[BUCKYBRONCO2021]

I get a similar pop in the morning when i forst start and make a left out of my driveway. Figured it was like when my knee cracks as i get up out of bed lol. Maybe i should get that checked out lol.

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