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Man, when I first read this I thought I might know, but as I finished reading I see you already removed and re-installed your shock. I had a similar problem on the front of my previous f-150. I was getting intermittant, (metal to metal) clanging noises. Turned out to be the top bolt on the pass side shock mount was loose. But, I know how you feel. It was driving me crazy, until it got figured out. I'd say put it on a lift and put your hands on everything, chances are you'll find it. I rolled all around mine on a creeper while it was on the ground and checked/shook everything, I thought. Just totally different perspective on things when it's on the lift.
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 06 F-250 6.0 PSD Harley Davidson Edition
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