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Officially joined the popping/clunking club today.. 5200kms ...
Condolences for your wife.
The initial clunk when you engage the 4x4 is not an issue, it's the continued clunk during driving that is scary. listen for it when you are accelerating or turning when in 4x4. you will notice it if it's doing it. if your truck is brand new, it probably wont have an issue.
Let’s get you out of the popping/ clunking club, oplersx. I suggest booking an appointment with your local dealer. To locate the nearest, use this link: Ford Find a Dealer - Ford Cars, SUVs, Trucks & Crossovers | Ford.ca Also, PM me your VIN, full name, daytime phone, and preferred dealer; I’ll loop in your regional customer service manager.
Kwasi