2001 Grand Marquis front end clunk

Wheel fell off about a month ago luckily as I was parking in my driveway literally at a stop so nothing was damaged, the ball joint was rotted out so we replaced. About a week later a slight clunky noise started and by the end of week the wheel had fallen off again as I was pulling out of a parking lot , again as close to not moving as possible luckily. The pin in the ballpoint had somehow come out. At that point we replaced both upper & lower on both sides. Clunking was gone for about a day then started up again so we replaced the sway bar bushings and clunk has gotten progressively worse. Literally have replaced everything in the front end! The wheels we have on the car are slightly large and rub if you turn the wheel as hard as possible, not sure if that has anything to do with it? At a loss at this point and looking for some ideas. Tie rods are new too

None of this makes sense. How about the A frame bushings where they attach to the frame. Only thing left.

Nope they are fine... Done upper/lower ball joints, tie rods inner & outer, sway bar links & bushings. ??? Not a complicated vehicle and I'm at a loss

You didn't say you did the bushings where the upper A frames attach to the frame,

I know this is an old thread. I'm just putting this out there for future reference. I've found on my 2002 Grand Marquis that the sway bar rubs on the frame. I get the same popping noise when turning at slow speeds. The noise is worse when the pavement is uneven. It has been rubbing ever since it was purchased new. I'm not a Ford fan, and will never own another Ford product after this one.

Sounds like your ball joints might not be the correct ones, or the A arm itself is worn out.