Clunk in floor boards
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Freshman User
Joined: Apr 2005
Posts: 39
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From: Centennial, CO
Clunk in floor boards
NEED HELP!! My 04 6.0 CC LB 4x4 has been to the dealer 5 times for the same issue. I have an intermitent CLUNK under my left foot. Sometimes it happens when I am turning and others when I pull straight ahead. It always happens after I have stopped. Sometimes after backing up. Just had new swaybar bushing put in yesterday, and other work done. It is not drive line lash, because that noise just started yesterday, and that is now occuring all the time. Does any one have any ideas that I can take to the Dealer tomorrow?
Senior User
Joined: Sep 2004
Posts: 235
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From: S.W. Michigan
It might be the damper (or whatever is in there) for the air conditioning/defrost flopping back and forth. The only setting on my truck that does not run the AC Compressor is vent. All others use some AC.
Try running with the AC/heat off or with only the vents on and see if it goes away.
Try running with the AC/heat off or with only the vents on and see if it goes away.
Post Fiend
Joined: Apr 2004
Posts: 19,098
Likes: 8
From: Great State of Texas
I don't know if these affect your truck or not but, you my want to mention these to your service folks.
TorqShift Harsh Disengagement Shifting from Reverse to Park:
Some trucks built before 11-14-03 may exhibit a harsh disengagement when shifting the TorqShift transmission from reverse to park. A cluck may also be heard. To correct, remove the control body and replace the manual valve with P/N 4C3Z-7D376-AA. Insert the new valve into the body plugged end firts. Install a new valve body gasket, P/N 3C3Z-7C155-DA. Broadcast
Message 1219.
Recall on 2004 TorqShifts:
Certain trucks built from 3-8-04 through 6-24-04 may experience a failure of the low/reverse planetary assembly. Specifically one or more of the planet gear pinion shafts may walk out of the carrier. If this occurs metallic contamination of the fluid will occur and will cause harsh or slipping shifts and/or harsh or delayed engagements in forward or reverse. Trucks affected by this recall will have the low reverse planetary replaced if no damage has occured, or will have the transmission overhauled and repaired as needed, along with replacement of the transmission cooler, if damage has occured. This recall has been extended until 3-31-06
Customer Statisfaction Program
TorqShift Harsh Disengagement Shifting from Reverse to Park:
Some trucks built before 11-14-03 may exhibit a harsh disengagement when shifting the TorqShift transmission from reverse to park. A cluck may also be heard. To correct, remove the control body and replace the manual valve with P/N 4C3Z-7D376-AA. Insert the new valve into the body plugged end firts. Install a new valve body gasket, P/N 3C3Z-7C155-DA. Broadcast
Message 1219.
Recall on 2004 TorqShifts:
Certain trucks built from 3-8-04 through 6-24-04 may experience a failure of the low/reverse planetary assembly. Specifically one or more of the planet gear pinion shafts may walk out of the carrier. If this occurs metallic contamination of the fluid will occur and will cause harsh or slipping shifts and/or harsh or delayed engagements in forward or reverse. Trucks affected by this recall will have the low reverse planetary replaced if no damage has occured, or will have the transmission overhauled and repaired as needed, along with replacement of the transmission cooler, if damage has occured. This recall has been extended until 3-31-06
Customer Statisfaction Program
Post Fiend
Joined: Apr 2004
Posts: 19,098
Likes: 8
From: Great State of Texas
Are you sure they checked this?
Bump or Clunk when Starting from a Stop, 4X2 Vehicles:
This may be due the slip yoke on the driveshaft not slipping smoothly. Separate the slip yoke from the driveshaft (index for reassembly) and lube the splines with Motorcraft P/N XG-8 PTFE (Teflon) grease.
TSB 04-26-6
(4X4 vehicle can be fixed in the same manner, although not covered by this TSB)
Bump or Clunk when Starting from a Stop, 4X2 Vehicles:
This may be due the slip yoke on the driveshaft not slipping smoothly. Separate the slip yoke from the driveshaft (index for reassembly) and lube the splines with Motorcraft P/N XG-8 PTFE (Teflon) grease.
TSB 04-26-6
(4X4 vehicle can be fixed in the same manner, although not covered by this TSB)
Thread Starter
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Freshman User
Joined: Apr 2005
Posts: 39
Likes: 0
From: Centennial, CO
I do have an aftermarket exhaust, but I had the clunk prior to the exhaust addition, and it has not changed since. It sounds and feels as though something shifts in the front susspension. The Tech said that the ball joints are all good, everything in the suspension is tight. I get the clunk, but the dealer can never reproduce it. Thats why I put this threat out there. I need AMO for the dealer.
Super Moderator
Joined: Jul 2004
Posts: 21,113
Likes: 3,939
From: Ohio
KW is right on, lube the spline shaft, even if that is not the problem it should be done. Left foot, cab mount and rear spring mounts, look for a worn rubber bushing. If your hubs are not completely disengaged that binds the front drive train when turning. Your bump can be transferring from another point. Do you have ESOF?
Ammo for your dealer....good luck.
Ammo for your dealer....good luck.
Last edited by Maxium4x4; May 16, 2006 at 04:46 PM.
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New User
Joined: Feb 2005
Posts: 1
Likes: 0
I have the exact same thing. It even clunks sometimes when I get in the truck and the weight shifts before I even start it. Feels like it's right under my feet. Please post results when dealer finds it.
BTW, I already greased my splines like others said, no fix.
BTW, I already greased my splines like others said, no fix.
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I have had the same sound and it is not consistent.
Post Fiend
Joined: Apr 2004
Posts: 19,098
Likes: 8
From: Great State of Texas
Welcome to FTE and the 6.0 Forum dacunn
When you get a chance check out our 6.0 Tech Folder
https://www.ford-trucks.com/forums/s...d.php?t=303583
When you get a chance check out our 6.0 Tech Folder
https://www.ford-trucks.com/forums/s...d.php?t=303583
Thread Starter
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Freshman User
Joined: Apr 2005
Posts: 39
Likes: 0
From: Centennial, CO
Dealer finally was able to fix the problem, good thing cause the warranty jsut expired. Anyway, they replaced the end links that connect the sway bar to the frame. That solved the problem so far. We will see in a few months if it changes. If the dealer says that they are going to replace the sway bar bushings make sure that they do the endlink bushings as well.
