Here is a little history of the leaf spring noise I have experienced with my 04 FX4. When the truck hit 20,000 miles I started hearing a clunk from the rear of the truck when driving slow in parking lots or turning into/backing out driveways. The put grease in between the leafs per SM 17777. The noise went away for a few thousand miles and came back. Next they replaced them. The noise went away until I hit 40,000 miles. They called the Ford hotline and were advised to do the SM 17777 again. Obviously Ford is aware of this problem but has no permanent fix for it. Every 04 I have ridden in or drove that has around 20,000 miles makes the same noise. The dealer had the truck for two days this week and I had the pleasure of driving a 1993 F-150 work truck beater the company has. This truck has 205,000 miles on it and it does not make noises from the leaf springs. Kind of frustrating. I get my truck back and still making the same noise, SM 17777 has worked for me once out of three times and only for a few thousand miles. Anybody else on the forum having these issues?

 

mine squeak but thats about it. im not worried about it its normal. but a clunk doesnt seem normal.....are they sure its not the driveshaft? ive heard of a few ppl on here that got theres changed.

 

I would agree that a squeak would be normal, I wish I just had a squeak. I am very confident it is the leaf springs because it was fixed when they changed the entire assembly around 20,000 miles. Like clock work at 40,000 the same noise is back.

 

Yea i have alot of squeaking and clunking from my leaf springs when I drive around. I hear it mostly over speed bumps and un-even roads or transitions..its really annoying and I am going to go to Ford when I have time for them to look at it.