Loud Knocking Noise

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Jan 29, 2004 | 11:42 AM

hunkybunny

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From: Cincinnati

Loud Knocking Noise

I've got a '03 Expy EB 5.4 with about 9000K, and since it's first drive, I've had a SERIOUS problem with LOUD clicking/clanking noise when letting off of the accelerator, and letting the vehicle downshift before stoping at a stop sign, or in heavy traffic.....it's not the brake, but if you let the vehicle idle, it's almost like a VERY LOUD metallic downshift happening in the trainy....and if you were to resume acceleration after taking your foot off, that loud metallic clanking sound happens again as the truck picks up whatever gear it left off in.

Anybody else having this metallic noise? I've seen nothing about it. Ford says it's normal, but the sound comes from under the hood....and when it clicks (single click) it almost moves the vehicle a bit....and the noise travels through the floor board. Imagine towing a trailer behind you, and you hear the metal on the hitch clanking, and that's the sound I'm talking about.

Any help would be appreciated!!!??? What's wrong with this truck of mine??? Is it a trainy problem?

Jan 29, 2004 | 12:13 PM

buzzard

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From: All over Texas

Huh? How could Ford say this is "normal?" Sounds like something is difinitely wrong with your truck. Make the dealership general manager (service manager at the very least) ride in your truck with you on a test drive then ask them if it is making normal sounds. If they give you a raw deal, take it to another dealership. You're bound to have many choices in Cincy.

Jan 29, 2004 | 12:25 PM

hunkybunny

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From: Cincinnati

Jim, I had the general sevice manager ride along, and he heard and felt the noises too, and told me it was a normal feature in the Ford transmission, and that there were no TSB's on it. So I'm assuming my case is a rare one at that. There are several more ford dealers I can take it to, took it to another about 3 months ago, and they said the noise wasn't loud enough to make such a fuss over....as I listen for weird noises, i'm picky. But this noise is obsurd.

Do you think this has something to do with the transfer case, the limited slip, or the transmission.

Jan 29, 2004 | 12:31 PM

buzzard

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They have had problems with the rear ends on the '03's so yes, that might be the culprit. I guess it could be a tranny or transfer case problem too. I've read where some have had their trannies replaced three or four times in a couple years.

You say since its first drive you've noticed the noise. Have you driven any others since? Did you test drive more than the one you bought? Maybe you should to determine if they make similar noises. My '00 is as smooth and quiet as a sleeping baby.

Good Luck.

Jan 29, 2004 | 12:43 PM

hunkybunny

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From: Cincinnati

Thanks for tips Jim, it's appreciated. I've driven 2 other Expy's that didn't do what my SUV is doing. I've purchased the Elite plan warranty, as I keep my trucks, and drive them into the ground, so if it's a drive train problem, I'm sure it will show it's face sooner or later.

Other than the problem I'm having, the 03 expy is great, it's tough, and powerful, with normal american car quirks, but that's not an issue to me. Foreign trucks just don't have the muscle we do here. If I could just get this problem solved, I'd shut my mouth, and smile.

Thanks for the help.