My 97 f-150 2wd, 4.6 with automatic and 15,000 miles makes a single clunk noise when coming to a complete stop. Sounds like it is coming from the differential or possibly the back end of the transmission. It did not do it when brand new, but started after about 3000 miles. Doesn't do it all the time, but probably 80% of the time. Switching O/D off makes no difference. I know if I took it to the dealer it would be the 20% of the time it would refuse to do it! Would like to hear any possible causes, or from others with same problem. The truck has had no problems otherwise.

 

A clunk noise when immediately launching a truck, or the instant before the truck stops during braking, is not uncommon. This is due
to excessive windup of the rear springs during these transient conditions. The slip yoke splines at the transmission output stick under this loading. Ask the dealer to liberally lubricate the driveshaft slip yoke with the blue service grease, D2AZ-19590-A part number. This should solve the issue if the clunk you hear is caused by the described condition.

 

I had the same clunking sound, had it at the dealer a few times, they kept reseting the computer because they did find an error code, this would work a few days, then it would be back at it. Finally they replaced the computer module? I will have to find the paperwork and email you with part numbers etc, but that was over 15000 miles ago and no problem since.

 

I had the exact same problem with my 98 2wd 4.6. After 3 trips this week they are finally fixing it. Also, expect it to get alot worse in a hurry. mine went from the clunking noise to rough shifts to losing the overdrive gear. I had to grab the shop foreman and take him on a ride before the would admit to any problem. All I can say is stick with it and give the Dealer hell.

 

I have a '97 F150 4X4 which I just recently purchased used and it has a "clunking" noise when first taking off from a dead stop. Initially I checked for u-joint wear, ring to pinion clearance and u-bolt torques. Everything checked out ok, so I took it to the local Ford dealer yesterday and had the service manager and trans/rear end tech drive the truck. They felt that it was coming from the slip joint on the rear driveline and showed me a factory service bulletin which shows a replacement slip yoke. Due to the fact that the vehicle has 43,000 miles on it I have no factory warranty. And the dealer will not replace the part for me even though it is an origianal part and original problem. The trans tech told me that he would just drop the driveline, clean and grease it. Most of the time this clears up the problem. So I guess I'll try that before having to take it the dealer and pay for Ford's screw-up.

 

Shovel: Give your dealer Hell. They really should cover you on the slip yoke. I had the same problem, it was under warranty though. I greased it up several times but it would never fully cure the clunking.

Anyway, I have had repairs done by my dealer under warranty as late as 42,000 miles. They told me that Ford will allow the dealer some descretion up to 50,000 miles to keep the customer happy! If you go back to the dealer and they won't budge you might think about calling Ford Customer Service. Sounds like you have a strong case if Ford has issued a service bulletin.

I don't know what they want for the yoke but if all else fails replacing it yourself would only take 30 minutes or so. Let us know how it turns out. Good Luck!

 

my 97f250 LD had the clunk when i bought it a couple years ago. my dealer siad greasing the yoke was only a temporary fix,about 9 mos. later a redesigned yoke was released. they put it on and no more clunk or greasing. ask your dealer as this is a known issue w/ early 150/250 s .

 

I have a '98 F150 4.2 auto 2x4 and have heard this thunk every now and then too. Originally I thought it was my spare tire not being tightly winched up. But, since reading this thread I think I will take my truck to the dealer and have it looked at. I only have 7K on it so it is definitely under warranty.

 

Hello,

I have a 97 F150, 13,000 mi., 4x4 Auto Trans, XLT, 4.6 L etc...

I have the same problem you guys are having!

I have taken it in to my ford dealer 3 times now. First time they put new shims in. Second time they adjusted the slip-yoke and then the third time ford told them to put a a new slip-yoke cover on. This seemed to work for a little while. It is back to normal now. The problem happens about 30% of the time. I don't know if causes wear or what but I think it is best to get it fixed. It will bug you some times also. Some of you guys mentioned you have got yours fixed. Can you please tell me what exactly your ford dealer did for you so I can tell my dealer and hopefully they can get it fixed

Thanks!

 

What exactly is the slip yoke? Is it the piece that comes out of the transfer case? Mine is a 4x4 reg cab 5 speed 4.2L
Rich

 

I have a '97 4x4 4.6 L. I have had this problem shortly after I took the truck. The dealer greased the slip yoke then replaced it with the new version, and now with 27,000 miles on my truck, its back. Sounds like a chronic problem. This is a known problem with this truck....a pre-existing condition. The dealer knows this.

 

I also have this problem with a 97 SC Off Road pkg (31K miles) 4.6L. I just purchased this vehicle used and thought it was a characteristic of the F-150 until I came across this thread. Question: Will this condition if uncorrected, negatively affect the life of the drivetrain or is it a nusiance type thing?

 

Have a 99 f150 5.4l, 3.55 with about 700 miles. Have noticed the clunk or grunt sound when i come to a stop then proceed to take off. Will take back to the dealer to see if they know anything. Noticed this happens after the car has warmed up.

 

My new 99 F150 Supercab (1600mi) has the clunk bad. Would like to share the Ford service notice # with my selling dealer. Anybody out there have this information? Love this truck, much better than the 97 GMC I traded, but I miss the gas mileage.(4.3L @ 23mpg) This 4.2L can't break 17 yet, I drive all highway miles (70 per day) Maybe gets better later? j.b.

 

Rich:
The slip yoke is the assembly that comes out of the back of the transfer case. The drive-shaft attaches to it through a universal joint.
I think the problem is simply a defective part. I don't think the piece can wear out that quickly. Grease seems to help short-term but the only long-term fix is replacement.