2-3 downshift clunk fixed
 

Took my 05 screw to the dealer for the 2nd time last Friday and the problem seems to be gone. Even if I try to make it do it, I cant. They did some PCM update. See attached:

TECHNICAL SERVICE BULLETINS 05-10-12
2005 F-150, 2006 MARK L T: HARSH 3-2 DOWNSHIFT BETWEEN 17-25 MPH (27-40 KM/H) - NO DTC"S - 4R75E AUTOMATIC TRANSMISSION - VEHICLES BUILT BEFORE 4/20/2005
SOME 2005 F-150 AND 2006 MARK L T VEHICLES BUILT BEFORE 4/20/2005, EQUIPPED WITH THE 5.4L ENGINE AND 4R75E AUTOMATIC TRANSMISSION, MAY EXHIBIT A HARSH 3-2 . DOWNSHIFT BETWEEN 17-25 MPH (27-40 KM/H) WITH NO DIAGNOSTIC TROUBLE CODE (DTC), AND A DRIVELINE CLUNK BETWEEN 40-50 MPH (64-80 KM/H). REPROGRAM THE POWERTRAIN CONTROL MODULE (PCM) TO THE LATEST CALIBRATION USING WDS RELEASE B37.4 OR HIGHER. CALIBRATION FILES MAY ALSO BE OBTAINED AT WWW.MOTORCRAFT.COM.
See TSB for complete details
EFFECTIVE DATE: 05/13/2005

*414084926* TECH HOTLINE CONTACT ID EXPIRES IN 5 DAYS FOR 1FTPW12575KD49387

Great post...thanks for the info - I'm going to pay closer atttention to my '05 SCREW that was built in 10/04....may need the same reflash.