Houston, do me a favor and try something. Go to your local parts house or machine shop and order some molykote. If you are capable of removing your rear driveline or could ask your local Ford dealer to do it for you, (you may have an in if you show them your video) thouroughly clean the splines and dry with brake parts cleaner. Apply a liberal amount of molykote on the splines and reinstall. I would love to know if this helps. My Raptor has not had the "clunk" so have not had to deal with it. Just a suggestion. The molykote will resist the t-case fluid better than the teflon.
FSM
yeah, I was thinking about just doing it myself anyway. The history with my dealer is I make an appt and it SITS for 3-4 hours then they spend a whole 30 minutes looking at it after they finish their morning tacos and have lunch.
MolyKote 7514? gimme the 411 and I'll order it online or find it locally here, and do it next week sometime.
Even if it lasts 1,000 miles for now its worth it to me to drop the driveshaft and do it up.
Can you tell me what the torque specs are on the rear Joint?, and should I re-grease the rear joint with the molykote while I've got it apart?