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I have an 03 crew with the 6.0 4wd. Has about 150k on it. No lift no mods.
At speed with the rpm about 1500, light cruise, no acceleration or braking, I get a knocking noise just under the drivers floorboard. More so under the right foot then left. Nothing in the steering or seat. It only happens under that coast type driving. I 1st noticed it only on well paved roads. In cali that's hard to come by, but i have been noticing it more and more. I looked under at the 4wd drive line, it doesn't look like the u joints are bad, and in 2wd it spins freely. Fluids all look good and my other truck has the loose body mount clunk, so I know it's not that.
my 2004 F350 did the same thing with the stock leaf springs, to fix it i replaced the front leafs with Pro Comp leaf springs and i installed Energy Suspension poly bushings in the front sway bar and end links. Now a year later i have that dam thud when i go through corners or up into a driveway. So far i removed the sway bar but i still get the thud since i have new ball joints, u-joints etc in the front end I'm consider the thud to be the leaf springs flexing around when i go into driveways its to make the thud sound. I too have checked everything and noting is loose or broken so I'm going with its the springs just flexing?
It's more RPM driven then speed. 40 - 60 mph its knocking about the same speed. I notice it more over smooth roads. My excursion has worn out leaf springs so I'm all too familiar with that chatter. Not sure if it is something in the transfer case. I assume the 4wd driveline is to spin freely in 2wd. It spins freely and has very little slop of lash to it.
Found the issue. Took it over to a shop to see what they think on a road test. Guy says hub right off the bat. I told him that I just replaced the hub less then 10k, hell less then a year. He smiled and said yup, bet ya did. Long story short is, Napa Premium Hubs are a joke.
drove the truck home after the repairs, and now it has a clunk when slowing, just as it goes down into 1st gear.
You can't help but love a truck you are so financially attached too