I talked to a friend of mine that has a performance shop and who does all the work on my truck and he said that when he takes it in to put the locker in the front that he will take the rear apart and shim it to try to take the excessive backlash out of it. I talked to ford and they wont do anything about it so i am going to take care of it.

 

Just got my truck back from Ford 33,000 miles and I'm starting to think they are flash happy. They located SSM 17624 for the clunk problem it required a PCM update for being out of range. Can anyone give some insite as to what is contained in SSM 17624? Also does anyone know what this means "Performed PID Monitor ICM"? I will post when I have a chance to test it in the cold. It is about 30 degrees up here right now so I should know in the morning? It seemed to be better on the way home from the dealer.

 

I didn't find that SSM but try these:

Clunk or Pop from TorqShift at 2-3 MPH:
A clunk or pop may be heard or felt on drive away after starting the engine, backing up and shifting to drive, usually around 2-3 MPH. This condition may be intermittent. It is the result of normal backlash (movement) between the splines on the low/reverse one-way clutch. Broadcast Message 1335

2003 6.0 Driveability/TorqShift Shift or Engagement Concerns:
This is now covered by Customer Satisfaction Program 03B06. It applies to trucks build through 2-23-03. The program will be in affect until 12-31-05. Ford is authorizing a free oil and filter change under this program until 12-31-03.
Some trucks may exhibit a rough surging idle in drive or reverse when cold , poor throttle response when cold, or low power after extended idling cold. Other symptoms may include harsh shift engagements, harsh 2-3 upshift, 5-3 downshifts and cold 3-5 shift flair. There is a revised calibration for the PCM, FICM and TCM--all must be reprogrammed as a set using WDS version 24.6 or higher.

 

Hi guys! Great site. Just wanted to thow in my 2 cents about the 2nd to 3rd "clunk". My '04 f250 has the same clunk as well as the reverse to forward "clunk" which on the 6th repair attempt, both left & right front leaf springs & hanger brackets were replaced. (FSE diagnosis) I picked my truck up on a friday, and the clunk was gone.(HOORAY!) But by monday the clunk was back. Tired of being the guinea pig, I started the "DSB" process. Even though my truck still has the clunk, I believe they were headed in the right direction. The "FSE" showed me the old parts and the left front hanger bracket had a wear mark ground in to it where the leaf spring was "shifting" back and fourth on the inside were the eye of the spring mounts in the bracket. Maybe this will help someone else with these problems. Buy the way, my '05 psd f250 sport package 4x4 should be here any day! Good luck guys!

 

I've got an '04 F-350 w/ the clunk too. It took 8 tries for the dealer to tell me that it was "NORMAL" (the last 2 tries were a week at a time). I get the clunk at 2-3 MPH and sometimes on the 2-3 shift too.

I'm sorry, but a "CLUNK" is not normal. I've always been a Ford fan, but this has been a bad letdown. I expected Ford to be better than just telling me its "normal".

I didn't pay over $40,000 grand for a truck that goes "Clunk". At least, since apparently then knew about the problem, the should be required to DISCLOSE this fact. It is obviously a material fact. How many of us would sign on the line if they disclosed this? How many buyers would buy your truck if they heard it clunk and you told them "Don't worry, Ford says its "NORMAL""?

I've battled my dealer on this now for months. Have complained for Ford's 800 number. Been told the first two times that some would contact me back within 5 business days, but that never happened. Was told the thrid time that they don't call back and that I should not have been told that. My dealer finally got an area rep out to look and drive the truck. He said it was "NORMAL", but would not meet with me or even talk to me.

If its so "NORMAL" why can't someone from Ford (other than the dealer) say it to your face. Would the Ford execs buy a $40,000+ truck that "clunks". I don't think so.

It's a croc... and Ford has dropped the ball on this. No one wants a vehicle that's "clunks" like this.

At this point I don't think that I will ever consider purchasing another Ford vehicle again.

Thinking of changing the badges on the side of my truck from

FORD POWERSTROKE TURBO DIESEL
to
FORD POWER "CLUNK" TURBO DIESEL

 

You need to determine exactly where the clunk is coming from.

First off, what wheelbase truck do you have?

Secondly, you need to get under the truck and check for obvious play in the driveline. It could be u-joints, backlash in the rear differential, play somewhere in the transfer case, or internally within the transmission (probably the outdated sprags used in the torqshift). Crawl underneath, and jiggle around on the driveshaft and u-joints and check for play. If there is no obvious play there, get in the truck and, while sitting still, manually shift the transmission from neutral to drive, lock in 1st, go to second, then third, then repeat several times over and listen for any metallic noises.

Give it a try, see what you can come up with, and report back

 

I've got an '04 F-350 Ext. Cab w/ 6' Bed. Unfortunate for me, I'm not a mechanic and don't have a clue what normal backlash and/or play in the driveline is supposed to be. I know that I've never heard of or been in another vehicle that "CLUNKS" and is "NORMAL". The repair is what I would have expected from Ford, or at least, "We're not sure what it is but are working on a solution to the problem Mr. Ford Owner". But no, instead, after 8 repair attemps, I finally got a copy of a Ford Bulletin that states that this noise is "NORMAL" and that no repair attempt should be made.

I wonder... if the truck just blows up, will Ford say that's normal too.

It just doesn't leave me with any confidence in the truck or Ford.

Would you purchase the truck if it "CLUNKS" and the seller said, "Don't worry about that, Ford says its normal"? Would anybody?

Its wrong of them to do this to us! I don't want them to buyback the truck, I actually love the truck otherwise, but I don't want any long term problems either. Besides, in Massachusetts, the lemon law doesn't even apply to me because its a business vehicle. Then again, aren't most F-350's used for business... lucky Ford.

As far as what and where the noise comes from exactly I can't tell and neither can the dealership's diesel mechanic nor his boss. They just tell me is "NORMAL" and don't want to pursue any further. All I know is that it sounds like a "CLUNK"... like someone raps the frame with a dead-blow hammer or something (you can even feel it in the floor through your feet).

 

You NEED to go to a different dealer. You CAN find one that will help you, even if it does require a bit of searching. Your best bet would be to go to your present dealer's largest competitor, and tell them how you need the truck fixed, and be sure to include who COULDN'T fix it. Let the vendetta between competing dealers work to your advantage. Obviously something is causing the noise and vibration, and no matter what, it CAN be fixed.

 

I've talked to several other service departments in the area, but they all tell me the same thing. Ford's TSP says that NO repair should be performed.

Leaves a real bad taste in my mouth. I paid $40,000 plus for a truck that goes "Clunk" and Ford WON'T do thing about it.

I'd get rid of the truck, but I don't think anyone would buy it... and if they did they would make me buy it back. Can't say I blame them. I can't make Ford buy it back because under Massachusetts law... business vehicles are not subject to the lemon law.

I DON'T want Ford to take the truck back... I would just like them to fix what's wrong with it, or at least be honest with me and tell me what's actually wrong with it. I don't need to be told a lie that the 'CLUNK' that the truck makes is 'NORMAL'. There is no such 'NORMAL' noise in any vehicle unless something is wrong.

If anyone out there figures out what is wrong with these trucks I'd appreciate you letting me know so that I can PAY a mechanic to fix mine.

In the meantime I know I'll NEVER buy another Ford again... and I've ALWAYS been a Ford fan... but no more. It's not because the truck has problems... but because they WON'T support and fix the problems... heck they won't even admit that it's a problem. I doubt that any Ford exec would PAY for a truch that goes 'CLUNK'.

 

I have an 05, and I hear a thump when the trans shifts from 2nd to 3rd gear. It sounds like it's coming from the transmission though.

 

Anyone else have this problem and get a fix yet???? I just traded in a perfectly good 01 Lightning F-150 and in the past 1k miles I have experienced this clunk when rolling off from a stop. It irritates me that this new truck has this issue as well as many others.

 

My 2005 has the 2nd to 3rd gear clunk noise too.I thought that I was the only one but after browsing several forums there are many out there.I have not brought it to the dealer as of yet cuz I dont need them ripping somthing apart that doesnt need to be.If I find anything out I will post back and let you all know.

 

I found this quote of a Ford TSB on another site:

" Some 2003-2004 Superduty trucks with torqueshift and 6.0 liter diesels..May exhibit a clunk or pop on inital engagement from reverse or to drive at approx. 2-3 mph or on low speed 2-3 upshifts. This condition be intermittent and is a characteristic of powertrain mechanical lash. No repair attempt should be made"

 

Yep, got the 2-3 clunk. I had this written up when I took it in for the rear seal leak. I got the same answer (a lot do it, so it's normal).

 

I have the clunk. Sometimes it is quite prominent others you hardly notice it or don't hear it at all.