Rattle from front right

[All_Grip]

I have searched high and low to no avail. The car seems to have a weird rattle (almost like the sound of a rotor rattling around on studs) when I go over little bumps. Applying the brake seems to make no difference in terms of eliminating the sound and he car drives fine and straight. This all started after the right side wheel bearing and the PTU were replaced by Ford. I took the wheel off and noticed the tech didn't put the small bolt securing the rotor to the hub back in, so I did that. I took the caliper off and reset it (both side of the car have a lot of play in the caliper rocking it back and forth), looked at the ball joints and tie rod, all seem good and tight. I noticed the rear engine roll restrictor mount was in pretty bad shape so I replaced that today, no difference. I am not sure where to look next. Since the sound is produced easily, I figured rocking the car would produce it but it doesn't seem to do it. I also noticed that it seems to only do it when the car is going straight. Any ideas?

 

[SHOdded]

I hope they filled the PTU to the correct level! How does the subframe look, did they touch it at all when they did the repairs? Is the bellypan properly secured, any of the fasteners missing? I would take it off and check to see if anything has been left behind in there. Also check the strut mounts for proper torquing.

 

[All_Grip]

Everything looks solid. I checked the axel but torque, hub bolts, links, ball joints and tie rods. They all look good. I did notice a minor amount of pat on the front links however upon inspection of the rear links both sides have a significant amount of play. They both physically feel the same so I wasn't sure if this was normal or not and if not perish pas its rattling and I am hearing it from the front.

 

[SHOnUup4]

Top strut mount bolts?

Rich

 

[All_Grip]

I checked everything as described and still can't track it down. I checked the inner tie rods as well and they seem fine. Possibly might have a sound resonating, making me think its from the front. I made a quick video of the rear sway bar mounts. Is this normal? Literally no effort needed to move them.

 

[Stanggt22]

http://vitalysmobileautodiagnostics...-reversedrive-2011-2015-ford-lincoln-vehicles

 

[Stanggt22]

Sway bar link looks fine...they are articulating links to allow for proper movement with the control arms.

 

[All_Grip]

http://vitalysmobileautodiagnostics...-reversedrive-2011-2015-ford-lincoln-vehicles

There is probably a good chance this may be it since the ******** at the ford dealership did my wheel bearing on that side. The problem wasn't there until this was done. It already looks like he tried to beat the control arm off the axel judging by the look of the control arm now (flattened on the edges as if hit with a hammer). He didn't replace the axel nut either and i dont believe its torqued to the required 258 ft lbs either. Ill check it out, thanks!

 

[All_Grip]

I stilled the trust washer...no change. I definitely can create the sound by grabbing firmly on the spring the car on the ground and rocking the car.