Ford Excursion :: Clunk Sound From The Back Of Vehicle Intermittently
Apr 10, 2013
Went for a drive last night in my "new" 2002, 4wd and which brought up some newbe excursion owner questions. First of all it has 95,000 miles on it and it is a V10. I noticed a clunk sound from the back of vehicle intermittently. u joints?, rear springs? or rear end?
Noticed that the front springs looked like they were sagging, is this normal or do I have an excuse to lift it? Also the shocks appear to be the original units and I figure that they are going to be on their way out. In the past I had good results with KYB gas-a just on a old F250 2wd.
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Our excursion usually sits unless we are towing or need to haul a group of people. The past three days my wife has been using it as a commuter. Yesterday she told me that two times at start-up she has heard a loud clunk/thump sound coming from the rear of the vehicle. At first she thought it was happening when she engaged the brake to put it in drive. Today she called me and told me the sound came just after start-up while the vehicle was warming up before the brake was applied. What this could be? I wish I would have observed it so I could give more details.
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I did a search and most of what I found is about front end/middle body flex, not rear end "clunk" noises.
Bushings?
I'm already planning on replacing all four shocks.
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I was running a small errand today, about 10 miles round trip. When I started out, I heard a small 'clunk' sound coming from the rearend. When I was on the return trip and making my last stop, the 'clunk' sound had become quite louder as I accelerated, and could really feel it. When I got home, I took a look and was expecting to see maybe a sway bar link detached or the bushing worn.
I did not expect to see two lug nuts completely gone, including the stud, as well as the holes in the rim no longer round. Big gouges in the rim around the remaining lug nuts, about to be sheared off! The other side had two missing lug nuts, however, the rim is still intact. What would cause such horrific damage? I am lucky that I was not driving on the freeway at 80 mph! This is my 2002 Excursion 4x4.
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My father in law has an 04 EX with the 5.4. It has a weird sound coming from the front passenger side. He listened to the jiffy lube kid who told him it was the brakes. I pulled one side completely apart tonight and the brakes are fine. We took it for a drive so I could hear the noise. It is coming from the passenger side up front. It is intermittent.
Doesn't matter if we hit a bump or pot hole. It sounds like a cat being run over. It will either last for a few seconds or just really quick. I crawled underneath and could not find anything loose. The first time I heard it I thought it was a shock. But the second time it was way too long to be a shock. And they are only a year old.
Secondly, it has a cat, and two mufflers..... Is this normal?
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I did some searching on brake and suspension related issues to no avail. When I let our excursion sit overnight, and get in it to leave in the morning...drop it in reverse and let off the brakes, I get a 'thud' noise in the rear of the vehicle.
It sounds like a brake pad sticking and immediately freeing itself when the vehicle is in motion. We don't set the parking break. The brake pads and rotors are new, calipers and pins moved freely, parking brake shoes seemed to be in great shape.
The only thing I noticed was a small leak from the rear axle seal which could possibly be saturating the ebrake shoes and causing them to swell and stick overnight. The only other thing I can think of is maybe suspension related.
I have noticed it when pulling forward into and out of a prolonged parking spot so I don't think it is driveline related. It also doesn't occur any other time except for after sitting for several hours.
It sounds like the spare tire is loose and rocks forward slightly and hits the back of the seat. I checked that also. Very faint thud..
2004' 4x4 with the 6.0 & 185k
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When I was reversing back and turning the steering wheel. I heard a metal clunk sound and it had happened twice in the past two days. Today happened after I released the parking brake and set it to reverse. What is the problem? Miles on the car is ~30700 miles.
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I have a Ford Explorer that my mechanic says needs a new trany. The vehicle takes a while to engage in reverse and does so with a loud clunk. Otherwise it runs good. I have 198K mi. It's an "02 4wd. Their asking $2,100 for the rebuilt trans. Wondering if it's worth it? May have reached the end of the line on this vehicle?
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Got a 2007 Santa Fe CM (Europe) with 160k km. I'm currently trying to figure out how to fix the clunk noise in the front of the vehicle. I am aware about the TSB 12-DS-002 where they recommend changing the drive shaft washer, but since that's a lot of work I want to make sure that this is really the problem.
The noise is not always there. Sometimes you can hear the clunk when decelerating, but not always. You can also sometimes hear a clunk when going from D to R. It sounds like a driveshaft has some play, and a change in the direction of the force causes it to slam into the other side. However, you can't feel it, so there is definitely not a lot of force behind it. You can only hear it.
However, I asked some guys to shift between R and D while I'm outside so that I can figure out where the sound comes from. However, murphy's law, it didn't made any clunk. And after shifting between R and D for like 20 times I felt bad for my transmission and stopped it.
The clunk is not always there, just sometimes. It doesn't really make sense to me, if its really play in a driveshaft it should be always there? Also the clunk started at about 155k km, now I got 160k.
Is there any further diagnostics I could do?
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I recently replaced the 2 rear Pirelli 19"s on the back with Michelin Diamaris 4x4. I left the slightly worn 2 front Pirellis on thinking NO big deal. WRONG! By not replacing all 4 tires at the same time I noticed a "clunking" noise coming from under the vehicle while under 20mph.
After trouble shooting at 2 different dealerships the second one concluded that I need 2 new front tires. At first they thought that the left front drive shaft was bad but after installing a new one "clunk" was still there. Dealer removed 4 wheels/tires from a new Touareg and placed them on my '04 and "clunk" went away. My '04 has the 4 corner air suspension and locking differentials as well.
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I love my Rig, however I wish I had more time to drive the Beast. My Ex sits at home about 90% of the time patiently waiting for it's next assignment. Service is reserved for family trips, once in awhile light duty towing, occasional date nights with other couples, loading up the kids & their friends to get ice cream, etc. I have other vehicles for my daily driver.
Curious to see how often other Ex DIESEL owners drive their rigs and what the average time the truck sits vs. being used. I'd rather drive the truck than let it idle for 1/2 hr.
My Truck has the 7.3 so, to keep the Diesel happy I don't drive it less than 20 miles when it does move. Diesel motor experts agree that driving a diesel less than 4 miles roundtrip is not good for the motor because the engine has not had time to reach full operating Temp. About to roll 260,000 and that 7.3 motor seems like it's just starting to get broken in.
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I have a shake at 60-78 mph. Have had the tires balanced three times, last balance is beter. I'm thinking of switching the wheels from my 05 F250 to the 03 Excursion to verify a tire problem. Will the factory F250 17" wheels fit for the test? Both are 4x4 vehicles. The truck rides smooth.
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I just got an Ex and am going to take it out next weekend and am trying to get it all squared away. What I am wondering is if there is a way to program it so all the doors unlock when shutting off the vehicle. Currently the drivers door will but I have to hit the unlock button to let everyone else out.
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On my 2003 6.0l Excursion, the 5R110 is having some issues with reverse lately. Sometimes when you put it in reverse it doesn't actually engage. The only way to make it "fall" into gear is by giving it a little fuel, which then sends it into reverse. Now here me out, I'm not hitting 3,000rpms when I do this, just a light raise in rpms will get it in gear. Solenoid issue, possibly?
I haven't noticed if it does this when it won't go into reverse or if it does it no matter what, but it will make a light clunk when going forward after using reverse. A very light, but noticeable clunk. Is this most likely a U-Joint related issue? Got under it and moved the driveshaft around, didn't notice any play at all, but perhaps I wasn't checking properly (wiggling it left and right).
Excursion is RWD (2WD) and has right around 183k miles on it, acquired in October with 172k miles, so not positive on previous history of the transmission. Also I know my gear selector mount is broke, so it cluster is off, but I certainly don't think that, in of itself, is the cause of my issues. Maybe I'm wrong?
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I've been having the loud clunk under the drivers side floor, that many others have as well. Did many hours of research and replaced the sway bar end links. Napa only had the left side in stock so I did it first last weekend and did the right side this weekend. One thing I noticed when doing the right side was the hole in the frame was all wallowed out. Drilled out the bushing in the upper end link and used a bigger bolt to fill the gap up. went for a drive and the clunk was way worse than it ever was still on the left side. So I took off the left one and went for a drive. Sure enough no clunk, the left one was wallowed out as well. So I did the same thing on that side and the evil clunk is finally gone. Just thought I would throw that out that if have a clunk after replacing the end links, Check the upper holes.
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So I installed my 4" Procomp lift, rancho shocks, extended length end links, brand new rear shackles, new steering gear and pressure & return hose and the truck still drives like complete crap...
When I was getting the front back together I couldn't align the front axle properly and the springs are leaning slightly...
Bump steer is terrible, wobbly sounding clunk from front end and she's all over the road.
Do I need an adjustable track bar? I assume the track bar is what's causing my axle to be off center... can I just unbolt it, center axle and re-bolt it?
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On my way home from work I was turning a corner and felt a pop / clunk from the front end through the steering wheel, and the steering wheel was no longer centered going in a straight line.
With the truck not moving, when I turn the wheel left and right, I can hear and feel a pop / clunk through the steering wheel. I'm assuming this is a ball joint failure?
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I am going to compile a List of Parts for swapping a manual transmission into an diesel Excursion. My search for the ideal vehicle has not been fruitful to any degree...I would like an F350 (or comparable with a stick) but the wife doesn't want a "truck"....and the only kind of vehicles I like to drive, are vehicles with a manual transmission...
I would be lying if I didn't call it an obsession.....but that is just the way I am wired. So the wife likes the Excursions....and I like the manual trans.....so I figured since the Excursion and the F250 and F350 are built on the same basic frame/body the swap would be "easy". Enough of that, my initial list looks something like this:
Transmission
Manual Trans Crossmember
Transfer Case (is it different between the auto and manual trucks?)
Clutch/Flywheel Assy
Pedal Assy
Slave Cyl/Master Cyl and plumbing
Dash Gauge cluster from a manual trans truck(without the Automatic Gear Select Display)
Steering Column from a manual trans truck
Shifter and Shifter boot
Wiring Harness for manual trans(?)
What else?
My "theory" is that all of the parts will be "bolt in". Besides the fact that this would be a serious undertaking, what problems could I expect?
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So now, what I'm noticing is a bit of a clunk in the steering. It's minor, very minor... but like any problem they usually start that way. The sound is very faint, you can't hear it under the truck, only slightly in the cab but you can feel it in the steering wheel, not so much when driving but when sitting still in a parking spot it's pretty obvious if you rotate the wheel back and forth. You can also feel it in the floor. Sometimes I'll notice this if I hit a bump while I'm driving.
Here's what I know, if you grab the tie rod, either end, you get a slight bit of rotation. Not just one end moving, but the whole thing has a small amount of forward back rotation (I'm not sure if this is normal) I had my girlfriend turn the steering wheel while I checked different components and there didn't seem to be any left right play on the tie rods. The boots look good on the tie rods ends, pic included, looks of similar quality of drivers side.
Then the kicker, here's where I noticed the gobs of grease on the top end drag link, pic also included. This was the last link I looked at, and I guess least expected.
So I guess I'm thinking this drag link is bad, but this is my first stop on the advice train. I wiped off the boot that was covered in grease on the drag link and it looked like its in fine enough condition but I also seriously doubt the shop that added the leveling kit just decided to slob grease all over the outside of this drag link boot. I have my truck oil undercoated before every winter but, that was some bit ago, and this looked more like grease to me.
Truck background: 2012 F250 6.7, I'm at 42,000 miles, 34in tires for most of that, and more recently added a 2 inch leveling kit (40,000 miles) and replaced the suspension all around and added a dual stabilizer. I had some noise coming from the drivers side wheel-well a while back and found that one of the end links on the sway bars was simply loose. Tightened up and all good to go. At 30,000 I got some death wobble. Replaced tires, the stock stabilizer had also gone bad, and had an alignment. Everything good since, but I'm thinking some of these problems now might be remnant of the bad tires.
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The leather on my steering wheel is showing a lot of wear so I will be needing a new one soon. I was curious if the new F250 steering wheels would fit a 2005 EX? I like the style of 2009, 2010 & 2011 much better that the stock wheel in 2005.
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When I turn off my Ex, the drivers door unlocks automatically, but the other doors remain locked. Is there a way to program it so that all doors unlock automatically?
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