I just left the dealership made an appointment to have this fixed next week. The TSB # is 04-26-6 addressing clunk or bump when starting from stop. I saw that a bunch of others had this same problem. I was wondering how long did the dealership take to fix your truck. Mine said they would need it the whole day (just to put on some lube). Also has anyone had problems with "clunk or bump" since the dealer performed this TSB upgrade?

 

I would like to know also. I have an appointment next Tuesday.

 

My first time took 4 days

 

My 05 FX4 Screw did the same thing. The dealer shimmed the rear end to get rid of the clunk when starting from a complete stop. While doing this they caused a vibration at higway speed (75 mph +) when letting off the gas. They are stumped and tried to fix twice. They say to get rid of it that I will get the vibe back. What a bunch of BS. Everytime they have tried to fix it went away and then comes back in about 2 weeks (700-800 miles)

 

I've had mine done 3 times now.. Each time they pulled the slip yoke and greased it. After it was done each time, it felt great. Accelerated smoother and no clunk. After a couple weeks it keeps coming back. I have an appointment next week and the service advisor told me the next step (according to the TSB) is to replace the driveshaft which is what they are going to do next.

For the first 3 times, it only took couple hours.

 

Ive been fighting this rearend shudder and clunk for over a year now ( search my screen name and you will see) anyway, I had the Ford engineer look at it last week and they put a shim kit on the rear axle. Basically a wedge type deal to rotate the axle forward. It's supposed to take the extra slack out of it so the driveshaft doesnt slam back and forth ( clunk ) and also get rid of the shudder on take off. It was great for the first few days, but it is coming back now. The service manager told me they had 2 different size shims, so if it comes back he will put the bigger shim in for me. If the bigger shim works and makes it feel like it did the first day they put the small shim in, it will be awesome. I never felt my rear that smooth.

Now, if they can just fix my rough idle and vibe issues i'll be happy.


BREW

 

They installed a new clutch pac in half a day for me, but same story as others--it only prevented the clunk for a week or so. I am taking it back soon. They mentioned something about rebuilding the rear end, but they my just mean install shims, we'll see.

 

This is not looking good... I hope Ford gets it $#*T together! I may just hold out until there is a sure fix to the problem, I hate having to keep leaving my truck with the dealer.

 

I get all my work done the same day I go for oil changes. They usually have all my stuff done that same day (mainly cause I will call ahead and let them know what TSB/Warranty work I want done....so they could have the parts ready).

I believe that the "clunk" TSB took all of the day to get done....

Those of you in the MetroEast STL area.....Koetting Ford in Granite City has got probably the best service department I have had experience with....their sales end seems to be lacking...but aren't most?

 

FORD-best built truck period

 

wstahlm80,

Have you had any problems since they did the TSB on the rear axle? Do you know exactly what they did to fix it?

 

They had my truck one day while trying to duplicate another problem. They greased the slip yoke and put a friction modifier in. The service guy said to give it a few miles to work. After 100 or so miles it went completely away and hasn't done it for the last 3,000. And mine was pretty bad.

 

I just noticed ours starting to do this, within the last week or so as well. I never even knew about the TSB, just got on here to see if anyone else was hearing a clunk noise when accelerating from stop (8k on truck). Good to see they are aware of it and "supposedly" have a fix for it. Anyone know where i can find the TSB so i can take it to my dealership with me and say fix this? We also have to get our headliner fixed as it rattles when driving around town, sounds like they forgot some clips or screws or whatever is supposed to hold it tight?? We'll see i guess, hopefully this can be fixed in a timely manner and only once would be nice as well. Just got rid of my '03 super duty 6.0 as i had nothing but problems with it, hope this truck doesn't turn out like my SD was.

 

That's what an older mechanic told me to do was add a friction modifier. He told me to look for something like Kendall Rear End Additive. He wasn't sure if it was still on the market though. It was supposed to be made from whale oil & eliminate the chatter in limited-slip differentials.

I'm going to mention that to my dealer when I take it back to get the shims removed. I'm convinced that the shims caused some kind of resonant vibration throughout the whole truck around 20-30 mph. This clunking crap is getting old. If it doesn't get fixed, what's the dealer going to say to me after he test drives it when I'm trading it in? "We'll have to make allowances to fix that clunking noise".

Matt

 

mine has been greased 5 times, and it is overdue for another lube job.....!

I have not looked at it myself, but could a guy drill and tap in a grease zerk?
the maintenance will still be needed "monthly" but could save a lot of time, not to mention what do you do when the warrany is up. mine is an early 04 and I'm at 32k miles, I suppose the board members are slowly going to start join the "you're on your own" group soon.

Ramb