This is the TSB for 1998-2004 F-150 4X4 vehicles ..

TSB 1-6-04
NOISE - DRIVELINE CLUNKING/GRUNTING NOISE OR SHUDDER SENSATION DURING LIGHT TO MODERATE ACCELERATION AND/OR BRAKING
TRANSMISSION - DRIVELINE CLUNKING/GRUNTING NOISE OR SHUDDER SENSATION DURING LIGHT TO MODERATE ACCELERATION AND/OR BRAKING

Publication Date: January 15, 2004
FORD: 1998-2004 F-150 ISSUE:
Some 1998-2004 F-150 4X4 vehicles with a one piece drive shaft may exhibit a clunking or grunting noise and/or a shudder sensation from the driveline. The condition will typically occur during light to moderate
acceleration from a stop and/or braking. This may be caused by the slip yoke not sliding smoothly on the transfer case output shaft splines.
ACTION:
To service, lubricate the slip yoke with Teflon Grease (D2AZ-19590-A). Refer to the following Service Procedure.
SERVICE PROCEDURE
1. Road test the vehicle to verify the condition.
2. Remove the driveshaft per Section 205-01 of the Workshop Manual.
NOTE: INDEX (MARK) THE DRIVESHAFT YOKE TO AXLE FLANGE FOR REASSEMBLY.
3. Lubricate the slip yoke with Teflon Grease (D2AZ-19590-A).
4. Re-index and reinstall the driveshaft per Workshop Manual.
5. Check the transfer case fluid level and add MERCON Automatic Transmission Fluid XT-2-QDX if necessary.
6. Road test to verify the condition is corrected.
OPERATION DESCRIPTION:
040106A Lubricate The Slip Yoke With Teflon Grease Vehicles With One-Piece Driveshaft TIME: 1.0 Hr.
　
DEALER CODING BASIC PART NO. CONDITION CODE 4602 42

 

It was a shift solenoid that needed replacing.

 

does the fact that the truck is in 4x4 or not make a difference for the clunking noise? i have a friend with an 05 super crew and it makes the noise as described. he took it to the small town "bring it back" mechanic who tore out and rebuilt the transfer case just to have the stubborn clunk remain. it only makes the noise in 2 wheel drive, but in 4x4 its quiet and sounds fine...my theory, based on what i've read here so far, is that with the front axle towing its share of the truck, the ungreased rear slip yoke doesn't have as much torque and subsequent stress being routed through it, therefor no noise in 4x4... any thoughts?

-Kenny

 

I just got done attempting this fix on my 06' f-150 2WD. It has had this sound since I purchased her last Oct with 37K now with 69K the sound is getting worse. I found this link and proceeded to get rid of the clunk. After dropping the shaft from the differential I realized that the darn thing had a spring in it b/t the band and the diff. This is new to me after much time under my 98’. The area where the spring is has a rubber grommet with compression clamps like on OEM half shafts . I did not have the correct clamps so I aborted the fix, but before I did I slid the Drive shaft back and forth on the spring several times. After reassembling I could not reproduce the sound at all. I figured I must have moved the grease around. This is the first time since I have owned the truck that it doesn’t clunk. I know it will not last without some honest maintenance but it tells me that is definitely where the sound/feel originates.

 

I am also experiencing this clunk from a stop. But I have a 2005 extended cab, with a one piece driveshaft. Is there a simple fix for my truck too?

 

Please tell me why the drive shaft needs to be aligned. I was not able to do so as I greased mine. I have never heard of alignment for a drive shaft. They can be removed and balanced, how would it stay in alignment then?

I hope I have not learned a hard lesson, but so far mine seems fine not going back lined up the way it came off.

 

hi all.... i have a question, my 04 screw 4x4 started doing this more after a 1"block and new shocks in the rear ? i did this to give me a little lift when carrying a load. could this have changed the axle enough to cause the clunk????

 

there is a clunking noise coming from underneath my 94 ford f150 4x4 if i hit the gas going up a hill or hit it from a stop it clunks like someone is hitting it with a hammer i have to hit the gas pretty hard tho i can feel it under my feet when it does it i was thinking maybe tranny mount? any help or advice would be great.

 

any chance the recurring noise isnt a u-joint? the service life for a factory ujoint in normal conditions is only about 30k

 

Why is the TSB only for 1998-2004 models but we are seeing this in 04-08 models? I have this problem but not from a stop. 15-25 miles per hour and accelerate, I get a clunk noise. Had the PCM reprogrammed twice but it didn't fix it. Does anyone think this procedure would work on my truck? 07 4x4 Mark LT?

 

my 2006 scab 4x4 does the same thing when i accelerate hard from moderate cruising speed.
if grease fixes this doesnt that say that the gears inside the slip yoke are wearing out and eventually need replacing?

 

i checked underneath today and i have a one piece driveshaft and there doesnt seem to be any play in the u joints or rear end as i cant budge the driveshaft even a smidgeon.

 

I have a 2006 F150 with limited slip diff too. Under mild acceleration (NOT from a stop) it will clunk, sometimes. It "feels" like its coming from the rear. Its getting worse.

So what's the first step - rip off the drive shafts and lube em up? U joints? Replace fluid?

 

If you are referring to a two piece with splines, if one U joint is vertical the other should be horizontal...turn one exactly 90 degrees from the other. It has something to do with harmonics in the drive line.