I bought a set of new Fox 3.0(non DSC) for my gen 1 .Front and rear . Same issue . Clunk from the front end . The Rear clicks, that's a given for an bypass /normal but the front almost sounds as if the spring is dancing around or something is loose while driving Over pot holes and man hole covers and cracks/expansion joints,speed bumps.
For me:
Replaced tie rods inner and outer oem , new uca oem . New lower ball joints "moog"and even rebuilt the LCA bushings from KHC/moog kit. KHC correct bolt/shank . Even adjusted the slack in the gear box(rack and pinion ) driver side had play .
But got that squared away . Whole front end is rebuilt . Running No sway bar. So can't be that Still has the clunk . Torqued and triple checked everything. No added preload from the way fox shipped them .
I talked to another member . He said he has no clunk/metallic noise from the front end . Non DSC 3.0 as well , The only difference that he has on his is svc UCA . And full svc tie rod (not the half kit) but he is running a stock LCA . He is running about 3/4 of pre load . (11threads)
So not sure if that's the difference between clunk and no clunk . Beefed up parts ? Tie rod or beefed up UCA. Or just the pre load .
So the ones who have no clunk symptoms . Please let us know what exactly what your running besides stock for the tie rods /UCA or LCA how much pre load your running .
Love my truck(box of rocks) but the clunk can't be normal . Considering some have it and others don't .