Hi, I'm new here.
My 04 f250SD 6L is doing the same thing. It mainly makes a clunk which I can feel in my feet when I'm slowing to a stop, regular braking. It also makes a rattling sound on uneven ground, sounds like front passenger side.
I would think if all of these trucks are doing the same thing, they should recall them!
I have been having this same problem as well. It was making a moaning noise and it felt like some one was hitting the floor board with a hammer.... Replaced the sway bar end links and it seems to have cured the feeling on the floorboard but still have the moaning. If I disconnect the sway bar and take it for a drive, no noise, no thump, all is good, put it back on the noise comes back... Patrick you had mentioned changing the sway bar monts as well, are those the mounts on the actual bar itself? Maybe that will take care of the moaning??????
sway bar bushings or ball joints (popping sound).
the factory sway bar bushings in the drop links are CRAP...they
tear...and most that ive seen torn are on the lower portion
of the drop link on the passengers side.
replacement (red or black) polly bushings from energy suspension
(available at summit racing & jegs) are about 35bucks for the set,
including the bushings that go 'round the bar @ the front/axle.
they need to be greased (periodically) though...or theyll squeek and
moan.
links to the part numbers and suppliers are in my "mods" link below
in my signature.