No clunk so far on '03, but this doesn't look promising...
 

time to e-mail herb again, obvious movement here.
http://images.fotki.com/v14/photos/2...y1st012-vi.jpg

later,
chris

You didnt really expect Ford to fix the "clunk" oil in the intake, and cracking fog light lenses when '03 is probably the last year of this body style did you? LOL.:banana: What else would you Ford Tech's do at the shop? (I've been there before! :D ) But it would have been nice.

:banana:

Bean Counters.


Do the harley's do this at all chris?

to be honest, I don't know, I really haven't seen many harley's come through for service, and I've never had a customer complain of this concern, but I suspect they have the same frame mounting points and they probably do the exact same thing.

yeah, there's about a half dozen or so 2002 HD guys at the other site who have this problem. i told them what the fix was, but nobody seems to want to listen to me and would rather just complain :rolleyes:

i haven't had any problems with my 00HD though (knock on wood)

While herb's fix looks good..I have just tack welded each of the 3 Gen II's I've had so far. They don't wear out and they don't clunk..
and I have no alignment problems with this .The first fix spoken of here....

Chris
My 01 has been showing signs of the bolt movement for 1 1/2 yrs now, and I don't have the "clunk" yet.Guess I just jinxed myself
I have had the washers in the console for a year now:p

what's the clunk? i have a 2000 and i was wondering if there was something i need to look out for on mine, thanks, Shane

shane, there are two clunks on all lightnings, one is from the lower control arm mounting bolts (one of which you can see in my picture above) and the other is the steering stops. both noises sound nearly identical.

the steering stops can be lubed with a dab of wheel bearing grease and the noise goes away. this one is ONLY heard at full steering wheel lock in either direction.

the lower control arm bolt clunk happens because the frame hole where the lower control arm connects is elongated supposedly for quick alignments on the assembly line. on alot of trucks this whole mounting point slides back and forth in this elongated bolt hole and clunks when it moves. this can be fixed several ways, one is herb's washers that are specially machined washers with a raised flange that fits into the oblong hole and centers the bolt and prevents movement, also alot of people simply weld the whole thing in place.

Ford came up with a TSB for the 99-00 trucks to address this concern. it involves replacing the stock washers with a "toothed" design. All '01 and up trucks are equipped with these parts, obviously they don't work, my '01 had the clunk the minute it rolled off the transport truck with 7 miles on the odo. :rolleyes:

later,
chris

Chris: I didn't want to be the one to ask........but I almost did. :D When you said you had put on 90 miles around town........ was when I was going to ask. Mine showed movement marks shortly after 100 miles. It's sad........but that's what Herb is for!!!

Great lookin truck!!!!

If you want to "peddle" those rear springs..........I might be interested. I likes to use the payload and tow also. :D

--------------
Rick

Not completely true. The fog lights have been redesigned.Hope the newer style stands the test of time.

VINNIE

apparently they haven't :confused:

https://www.f150online.com/forums/sh...hreadid=101638

:thumbsup:

I wonder if the heads still like to launch plugs ????I bet they do, we all know Ford's official word on the problem is "What Problem?"

--wes

Yeah, the "new design" is working great. Had mine replaced with some supposed newer version a few weeks ago...the passenger side has 1 crack in it already....and I havent put 150 miles on it since they were installed...just been washing her and putting her in the garage. :D But as long as they keep replacing them I'll keep getting new ones. ( 3rd set so far )