A Ford tech's take on "THE CLUNK" (THE ONE and ONLY CLUNK THREAD)

[IRONMAN]

I do notice after longer or harder driving it seems to go away, but it's always back in the am.

The extra heat would cause the metals to expand so less play in the shaft I take it.

 

[pirate air]

I couldn't bring up the link to the F150 forum that described the fix regarding the "flange" (my internet sucks atm), but based on what I know, I am 99.9% sure I understand what was done. The flange can be referred to as the pinion flange. It does two things by being one of the components that mates the drive shaft to the rear end, and it also keeps the pinion gear in place. The nut (pinion nut) that holds the flange can only be seen when the drive shaft is removed from the differential. The nut threads directly on to the end of the pinion gear shaft. If the nut comes loose it will allow the pinion gear to move back and forth. This also allows the pinion gear bearings to become loose against the races which will cause up and down play. Its possible the nut coming loose caused that guys clunk, I've seen it happen on really old cars/trucks and in theory it makes sense. But I doubt this is the "big fix" to the clunk problem and I would highly advise anyone NOT to mess with the fastening torque on their pinion nut. The nut pre loads the pinion bearings using a crush sleeve, a lot of care has to be taken in how and how much the nut gets tightened. Too much and you burn up bearings, to little and you get excessive play. IF the pinion nut fastening torque was to blame for all these clunks I would expect to see people complaining about vibrations, howling noises, clunks/bangs at all times and eventually total differential failure (rear tires locking up and really cool carnage noises).

 

[Big Game Hunter]

update on the clunk. new ford TSB

i just left my dealer and they informed me that FORD issued a new TSB on March 6, 2011 which recommends nothing is to be done at this point and that they are still investigating the clunk for a technical fix. The TSB, so I am told, indicates that greasing the slip yoke or replacing the drive shaft will not cure the condition and that the clunk will return.

 

[SCelebs]

i just left my dealer and they informed me that FORD issued a new TSB on March 6, 2011 which recommends nothing is to be done at this point and that they are still investigating the clunk for a technical fix. The TSB, so I am told, indicates that greasing the slip yoke or replacing the drive shaft will not cure the condition and that the clunk will return.

Yea, the past lube job lasted me 100 miles and the clunk was back. Let it be known, save yourself the time and deal with the clunk until Ford has a permanent fix.

Jeff

 

[warrior]

the clunk, updated

had the screw in for 1st oil change, middle perch adjustment and 'the clunk" again. tech couldnt lube again: Ford issued this on my bill........
2011 Raptor vehicles may exhibit excessive clunk or a chirp/slip bump comdition from the drivline on acceleration from a stop or when bringing the vehicle to a stop. Greasing the slip yoke or driveshaft replacement will result in repeat repair attempts. Engineering is investigating through the quicker service fix (QSF) process, and is developing a service repair procedure. Continue to onitor oasis updates. Effective 3/9/2011. "

 

[SPRSNK]

So we sit and wait listening to that stupid clunk?

 

[swoop1156]

So we sit and wait listening to that stupid clunk?

Yep. Been that way for years. Not gonna change anytime soon. I hope that I am wrong, but Ford trucks have been doing that since about '97.

 

[SPRSNK]

/mutters

Sounds like the clutch issue with 07-09 GT500's. Finally replaced it with a Spec Stage 2+ and fixed it.

 

[CineSLR]

Lord I hope an aftermarket part comes available to fix it. They would sure make a killing...

 

[Hoffer]

Had them lube mine and only lasted 2 days. If I knew how bad and loud it was , I would have never bought the truck. Keeps getting worse every day.
Major flaw for an otherwise badd ass truck.