Ya know, this thread is a great idea. Despite the clunk, my Raptor has been great. It has the ability do two things fairly well (on and off road travel) & for the most part it is fairly well thought out.
As to why the clunk wasn’t discovered during the test /R&D secessions. I think the problem is due to a tolerance or material conflict. I doubt the same people make both the output shaft and the yoke. They were both given dimensions of the parts needed with some +/- tolerance as well as material guidance/ requirements. When the testing phase was going on the parts came from new fresh tooling, and were probably not assembled on a regular line. Once testing was done and production started things changed. Who knows what it was? It could be that someone changed their material a bit and that new material expanded more than anyone thought. Heck, it could be that the yokes got slightly corroded when they were traveling from their factory to Ford's. Either way, it's fixed.
One thing I like ask people is: Do you do your job with the same level of perfection you ask of others?
Is everything your company does perfect?
And most importantly, can you see into the future? Can you anticipate every possible failure & fault that might occur?
I kinda doubt it, because I spend a lot of time fixing things that are far from perfect either due to poor design, poorly built or just because shit happens.