I have a New F-150 4X4 i AM ALSO having problems with a clunk in rear end. Brought it to dealer 3 times they told me this is normal. They put and additive to diff. No Change if any one has suggetion please respond

 

Welcome to FTE!

This thread will be moved to the 2004 truck forum.

 

You'll want to be specific about when the sound occurrs (i.e. speed, conditions, etc)

 

Occurs at take off. Sometimes it knocks once nad sometimes it knocks twice.

 

its not normal
Had the same problem with my 04 4x4

I took it to the dealer twice. the first time they said the drive shaft needed to be greased (brand new truck?) solved the problem for about a week.
the second time i took i told them i wanted the drive shaft replaced which they did (they also replaced the accelerator pedel sensor because i had a loss of power for a second when i was pulling out of a parking spot I'm sure this is not part of your problem though.) this fixed the problem big time. I think this may be
your problem (driveshaft). but anyway heres what my invoice said hope it can be of some help to you.


Cust states clunks on take offs verify 826
ordered parts
recomend replacing the drive shaft=the splines
to the transfer case and binding also removing
rear transfer case housing and cleaning the output
shaft and replacing the transfer case out put seal
and retesting


Good luck

 

I have a 2004 SC XLT long bed Heavy duty model. I brought the truck in for wheel shimmy at 60mph and they put senors all over the vehicle and test drove it. They determined the rearend was bad and replaced it. I did notice some noise from the factory rearend now that I have a new one to compare it to. Once in a while the old rear would "clunk" from a dead stop take-off. The shimmy was fixed by road forced balancing at another company other than Ford. My dealer does not even have a machine for that service. There was a service letter on bad rear-ends back late last year. Your truck might have received a defective rear. My truck has been doing fine since the replacement.

 

Oh, I forgot to mention that my truck was built in 10/03. That was well after the service letter came out.