Update: 5-9-24
Here is a video of my friends 2021 raptor no thump/binding (55K miles). The shaft has a different finish and the rubber boot on the bottom is a different color. The head of service asked me to write an email to him describing my issue and include all my videos. He sent my email...
Mine was just he driver side and it was replaced 09-23-2023. Mine would squeak every time the vehicle recognized the key (as the actuator cycled twice), every time I started the truck and every time I lightly tapped the throttle. Does yours do it when you tap the throttle? Try a different dealer.
I hear a thump right when it starts (around 1 sec) then I hear the same thump right as it stops (around 5 secs), Is that part of the problem your having?
No, it was more of a dry sharp door hinge squeak. I looked under the hood at the waste gate actuator as it moved it made the noise. They should not make those types of noises. Why does one side do it and not the other??????? Why don't all the trucks make the same noise????
Yes, it sure seems like a tolerance issue. I had to figure out the issue myself and document it with videos. It's very clear where and what the issue is.
There is always movement at that location with flex or whatever. That part should not bind under heat and cause the thump. They checked all bolts and brackets in that area for torque. Your lower shaft moves but I'm assuming it doesn't bind/thump like mine. I'm thinking about putting a GoPro down...
The thump is definitely coming from that part. That's the only thing i'm moving and it's the same sensation I get in the steering wheel. I had my friend move it just as i'm doing while I sat inside and held the steering wheel. Does yours make that thumping sound in my video(turn up your volume)...
Here is the new (second replacement updated part# NL3Z-3B676-B) lower shaft after driving it home from the dealer (hot). You can see the grease where the yellow rubber is sliding on the shaft. Still thumping...
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