The drive shaft is the clunk TSB from Ford Motor.

Mark the shaft/Pull it/Clean tail shaft spline with brake fluid/ Apply thin coat of Teflon grease/ Reinstall.

 

Here's my story...

I have had this clunk for 3 years. Multiple people told it was the slip yoke on the driveshaft. I lubed it a few times but it only lasted for about 2 weeks then it would clunk again. So about a month ago I bought teflon grease from Ford. I planned to lube it soon, but before that I removed my 3 inch block and am riding on stock springs + an add-a-leaf. So its about .5-1.0 inch lower than stock. I know have NO CLUNK what so ever. It must be that the distance is shorter between the t-case and the rearend, so no sliding is needed. When I had the 3" block with AAL it had a REAL bad clunk. So all is well for me. Sorry for the novel....

 

Has nothing to do with it. You just weren't as greased on the spline in the previous position.

 

I've had this same noise for the last 20K or so. I'm about ready to get serious about finding what it is. My feeling is that it's in the suspension (in my case) ... I've got close to 100K w/ no suspension work, and I'm thinking it's about time! Keep us posted about what you find.

 

Seven,

Have the calipers ever been compressed to make room for new pads?

 

Yeah I figured this out last weekend. I just tightened the DS front caliper bolts and VOILA! No more clunk!!! Thanks for all the insight guys. Those of you with the same prob give it a try.

 

Thanks for the info and posting back

 

No prob! I still can't figure out why it did it though...Do you think since there was play in the caliper that it just needed to seat itself on the first stop after rolling forward? What's funny is that it didn't do it at every complete braking stop. I'm no psychics major so anyone else want to take a shot?

 

It's most likley the stock rubber line, They start to collapse inside and can't supply enough fluid to pressurize both pistons equally. You can really tell when the line is restricting in this system, The front end vibrates like hell every time you try to stop. Twin piston calipers should have braided supply lines OEM IMO - Stock lines don't last very long.

I finally replaced everything @ 257,000 miles- Hard lines as well, - I tell yuh, it's a night and day difference, specially when towing. I went with steel pistons and love them. Has that new truck feeling when braking.