I bought my E-350 6.0 diesel in June, and it now has 8,000 miles. This is my 3rd Econoline, and my first diesel. It has been recalled once for having the wrong front springs, and developed a differential seal leak at 3,500 miles. The engine runs fine, I am impressed with the noise damping feature, and I get over 20 mpg on the road when not towing.
From day one it has made a clunking noise just after shifting into gear. At first I assumed it was a normal gear engaging sound, but soon noticed it was intermittent and getting louder. Early on I thought it could be a rear brake caliper sticking. A typical event goes like this: The vehicle has been warmed up then parked for a few minutes while running into a store or something. It is started and shifted into reverse and backed out of the parking spot. When it is shifted into drive, it rolls forward before pushing on the accelerator then when some torque is applied to the drive train there is a clunk sound from the rear end. Some times it is loud enough that a passenger hearing it will comment on the noise. Some times only I notice it. Some times it doesn't make the noise. The clunk doesn't happen when the vehicle is cold. It is not coming from the brakes, they were checked by 2 dealers--and the clunk will happen without using the brake. The clunk will only happen when the transmission has been shifted into neutral between changing gears.
One dealer tech (a younger guy) said it was the yoke and that he lubricated both. THis did nothing to stop the sound. Another dealer tech (one of the most experienced in my area) says he thinks it may be a defective spider gear or spline play in the rear end, but that it needs to get louder for him to be sure before any repairs can be made.
My concern is that it will be out of warranty before I can get it diagnosed and fixed by Ford--and that it will be a problem when towing.
Any thoughts?

 

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Hang around you will get some input on this

 

Here it is from Ford bulletins:

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

 

I would love to see the original Ford bulletin on this. Another thought: the vehicle does not have to be reversed and shifted back to drive to cause a clunk or pop. Sitting at level stop, shifting from drive to neutral for a minute, shifting back to drive, pulling away normally, after moving a few feet, the clunk will occur--intermittent.

 

I've got an '04 F-350 and had it in to the dealer 8 times (the last 2 times for a week at a time) before they told me that it was "NORMAL" and that there was no fix for it. They even gave me a copy of the Service Bulletin.

I've complained and complained... to the dealer... the manager... the service manager... Ford's 800 number... even finally got them to send someone out (supposedly, although they would not let me meet him (makes one wonder)) all to no avail. They keep telling me that its NORMAL. NORMAL my rear end!!! They should have told us before we put our hard earned cash on the table (mine was over $40,000) and instead of a Power Stroke Diesel I've got a Power 'CLUNK' Diesel. Definately NOT what I was looking for.

I've had several passenger's comment on it when they hear it... usually it goes like this... "What was that?... sounds like something just fell off the truck." Oh don't worry I tell them... Ford says its "NORMAL". Then they look at me funny. One guy told me if it was his truck and the dealer wouldn't fix it... he would have driven it right through the showroom. Not a bad idea but I have a family to worry about. And I'm out over $40,000 for a truck that I can't even sell. Who's willing to buy a truck that "CLUNKS" and then the sellers says... "Don't worry, Ford says that's 'NORMAL'".

I've been a loyal Ford Owner since I was 18. But this leaves a bad taste in my mouth. I'll NEVER buy Ford again.