HELP - Rear End Clunk/Pop (no not that one)

I recently installed new shocks and Deaver springs on my truck. This was my first time installing real leaf springs, and tried to follow the directions as best I could, but the job was pretty straight forward. On my first test drive I could immediately hear a clunk and popping noise from the rear end when backing out of the driveway and the rear axle started to articulate. Chocking it up to new springs I didn't think much of it, and hosed the springs down with fluid film.

It's been a month now and the clunk hasn't gotten any better. Ive double checked all bolts, sprayed the springs down with lube every weekend, and even contacted Deaver about the noise. They told me to make sure the keepers weren't contacting the side of the leaf packs. They aren't....

Does anyone have a clue where to look next? Slip yoke was greased, no signs of ovaled shock bolt holes, shackles or spring mounts, U bolts were torqued as best as I could, and no sign of anything rubbing against each other under articulation.

The only thing I can think is the leafs are shifting left to right in the pack when it articulates. Also I can't replicate the noise while parked, only when driving and turning.

Did you ever figure this out? I have the icon springs and I get a pop sound from both sides (in the rear) when I’m doing low speed turns. More common when it’s raining.

When installing leafs make sure to only tighten the u-bolts when in the air, at most 40lb-ft torque to just hold them in place. The final torque is done with the tires on the ground as you want them to settle in place properly when you torque and bend/stretch the u-bolts around the leafs.

Adam Etheridge said:

Did you ever figure this out? I have the icon springs and I get a pop sound from both sides (in the rear) when I’m doing low speed turns. More common when it’s raining.

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make sure that the pins protruding from the leaf packs are 100% in the perch locator holes. it is VERY easy to think they are in properly, especially if you used an impact to tighten the ubolts. The pins are hardened steel, the mounts on the axle are mild steel. the pads will bend and hide that the pin isnt in the hole.

as for the icon leafs, the second leaf has a military half wrap, it can hang on some shackles, including the factory ones, when the spring gets to full droop. overtightened shackles can make the scenario even worse.

Not too resurrect an older thread, but I too have Deavers and have a ‘pop,pop,pop’ sound from the rear of my truck. Seems to do it when braking, but only when I’m almost stopped. Then I hear it again just as I take off. I also have the clunk too. I have completely given up on any dealership helping with it and just grease it with Ford’s recommended setup, which doesn't but a couple long drives. I figured the popping was contributed to the yoke, but it may not be. I only drive my truck maybe once a week, so I don’t have a lot of time to investigate it. I’m going to double check all clearances on my Deavers and see if they could be the problem.

I just put icons in and have a clunk on each side stopping/starting and over large bumps. Everything is tight. It’s frustrating, I’m about to pull it all apart and go though the leafs, shacks shocks etc, only 20,000 miles but it’s not stock so the warranty won’t be much help.

North796 said:

I just put icons in and have a clunk on each side stopping/starting and over large bumps. Everything is tight. It’s frustrating, I’m about to pull it all apart and go though the leafs, shacks shocks etc, only 20,000 miles but it’s not stock so the warranty won’t be much help.

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I'm not sure if you know but the front bolt for the leafs is 258 ft-lbs. of torque.
Torque specs | Ford Raptor Forums
That's something your not going to get with a standard 1/2" ratchet or a standard wrench.
We're talking big 24"+ breaker bar (preferably a torque wrench) or add a 2 foot pipe on the wrench.
Or a impact gun with 250 ft-lbs. of torque capacity.

Also the holes in the front frame horn have been known to egg out,
people fix this with welding washers on and getting a longer better bolt.
I need to do this and will get it done once I get the Krazy House customs.

Adam Etheridge said:

Did you ever figure this out? I have the icon springs and I get a pop sound from both sides (in the rear) when I’m doing low speed turns. More common when it’s raining.

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Did you ever get to the bottom of this? Mine has done this exact same thing since the first rain after the install, that was 2-3 years ago. When its dry its totally fine, but as soon as there‘s moisture up the air it sounds/feels like a $2 hunk of crap. I’m basically at the point where I’m thinking about switching back to stock…

- Travis

Same issue. Installed icons on the rear about a year ago and get a clunking only in the wet. Only when turning into bumps on the road. Fortunately I live in a mostly dry area and have a short memory. So I forget about it until I drive in the rain or mud. Then it annoys the hell out of me. Taking her out to Moab in few days, hoping for dry conditions. Anybody find out anything definitive on this??