Hey KKirt, thanks for the reply on the slip-yoke. I thought that was where it was. Mine has been clunking since day one, I just never thought of it as a problem. I brought it into the dealer, and they ended up replacing both axle in the rear end!! I kinda knew that this wasn't the problem. What is the bulletin # on this issue? I want to go into the dealer and TELL them to replace the dang thing, once and for all be done with it.

 

I have I think the same thing. The noise I have happens at 22 MPH on the money. Probably 80% of the time. Ford replaced tranny, and it still is there. 4.2L with 4spd. OD Tranny.4x4 They reprogrammed computer once. Helped for a few days. Now replacing rear end parts. Will keep you informed!

 

To Randall, when they put in the new computer module, did your gas mileage increase?

 

Randall here, I had to change my username, Randall wasnt working.. I'm sorry , it was a while ago and I dont have the records for gas mileage, I couldnt find them anywhere. Seems i did notice 1 1/2 to 2 mpg increase though. I do remember it affected it.

 

To all: mention Technical Service Bulletin (TSB) # 97-13-21 "Clunking or Grunting Noise from Driveline" to your dealer, this should get him going in the right direction.

 

MDW79,
I had the same problem but I cured the problem by dropping the drive line and after cleaning the grease off I used emrycloth to buff off any tiny burs that happen to be on the spline theeth, lubed it up gave the drive shaft a 1/4 turn, reinstalled and no problems since.

Nino

 

Just took my 1997 F150 4x4 in for oil change and mentioned the clunk on startup. New slip joint to be installed under warranty.

 

Also, might be, just to be sure... from about 3000miles on I had clunk/groan from drive line. Got worse as time went on, after much dealer head scratching, my tire alignment shop came up with the answer (in my case):
One of the two main bolts which hold the tranny in place to the frame (hard to see - hidden up under the cross member)fell out or was never there. This is not as uncommon as you'd think. (A 1995 or so F150 Lighting came from the factory this way, the owner of which works at my tire center.) This caused the drive line to moan and groan and clunk whenever you accel or decel, even in traffic, with varying degrees of noise level. Every moan also caused the pinion to 'tweak' some. Eventually leading to a leaky pinion seal. Dealer rebuilt read diff, and still had noise/moan/groan. I went stright to my tire center to ask 2nd opinion. And they went stright to tranny bolt question - problem solved!

 

I had the slip yoke clunk noise on my 99SD 4x4. I removed it and drilled a hole in the side down near the universal, I then tapped it and threaded in a grease nipple. I filled it with grease and the noise disappeared. I will now grease it on regular intervals when doing the rest of the truck, and when and if the noise returns, This setup is how some of my older trucks came from the factory. This would be a good TSB or recall for FORD to adopt.

 

This is for 99SDKT, Whenyou installed the grease fitting, won't this throw your driveline out of balance? I know this is a little fitting but?? Sounds like an idea to me.

 

Rich
No it has not thrown my drive line out of balance, as it is installed as close to the rear universal as possible, and weighs next to nothing

 

I have a brand new 99 4.6L auto with only 350 miles and I hear clunking. It seems to happen when I am going around 20 mph and accelerate. It also happend when Im going around 40 and decelerate. Can anyone help me?? Thanks.

 

Well. its me again! The dealer just put in new gears in the rearend, and it is still making the noise! Surprise surprise!! Now they are replacing the transfer case. They told me that the 98 trucks have the new slip yoke, and the TSB was for 97's. Oh yeah, the 99 f150 that I had as a rental did the same thing!!!! It was a 4x4 with manual shifter, not electric. How bout you others, what kind of transfers do you have?

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Pablo.... Try what I mentioned in the above post.

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97 F-150 XLT 4.6 V8 with OffRoad package,Superchip,flowmaster,K&N Airfilter kit

 

This message is for 99sdkt, how did you go about drilling out your slip yoke? I want to do that to mine but I am not sure. I can do all the handy stuff, i just need some input.
Thanks
Rich