Axle clunk

[HuntingPudel]

I do not have a clunking or rattling noise. I have a low frequency rumble as I back down my driveway. It was not present the first few weeks after I brought my car home. The weather has been damp recently, so I am correlating the noise with damp weather. My assumption is that my noise is rotor oxidation due to the dampness. It is not oxidation that is visible to my eye in the low light of the early morning. I do not generally hear the noise as I back out of a parking space at work in the afternoon, even if the weather has been wet. ?‍? Of course I could just be all wet here. ??

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[BMT1071]

I do not have a clunking or rattling noise. I have a low frequency rumble as I back down my driveway. It was not present the first few weeks after I brought my car home. The weather has been damp recently, so I am correlating the noise with damp weather. My assumption is that my noise is rotor oxidation due to the dampness. It is not oxidation that is visible to my eye in the low light of the early morning. I do not generally hear the noise as I back out of a parking space at work in the afternoon, even if the weather has been wet. ?‍? Of course I could just be all wet here. ??

Did you swap out the tires, or are you still running the summer tires?

 

[Mirak]

My car makes the same noise, going left or right, it's not a "clunk" sound, it's more like a rattle.
I don't think its the half shaft axles.

Right, I think the "clunk" in the thread title is an unfortunate mischaracterization. Everybody who has posted a recording is experiencing more of a rattling noise. To me, it sounds like gravel knocking around in the wheel well, but maybe that's a unfamiliar sound to some city-folk.

 

[Mirak]

So as I read more about this, I can understand why there might be a little confusion between half-shafts and cv joints. We've got two half-shafts (aka axels) in the front of the car, one for the right wheel and one of the left (hence "half" shaft). Each half-shaft has a "constant velocity" (CV) joint on each end - the inner joint connects to (in our case) the electric motor, and the outer joint connects to the wheel.

It is typically the CV joints that are the point of failure - not the axels themselves. But it could be more cost effective to just replace the entire half-shaft assembly, which includes the CV joints on each end, rather than just replacing one or more CV joints. Maybe Ford only recommended that my service center replace the CV joints (not sure whether inner, outer, or both), or maybe the service center is just telling me they are replacing the cv joints when in reality they are replacing the entire half-shaft assembly on both sides. We'll have to share paperwork when all is said and done.

How to Tell if You Have a Bad CV Axle or Half Shaft (repairpal.com)

And by all means, point out any corrections to what I posted above because I am NOT a mechanic.

 

[HuntingPudel]

Did you swap out the tires, or are you still running the summer tires?

Still using the summer tires since the temps have been 50s or higher. ??

 

[HuntingPudel]

So as I read more about this, I can understand why there might be a little confusion between half-shafts and cv joints. We've got two half-shafts (aka axels) in the front of the car, one for the right wheel and one of the left (hence "half" shaft). Each half-shaft has a "constant velocity" (CV) joint on each end - the inner joint connects to (in our case) the electric motor, and the outer joint connects to the wheel.

It is typically the CV joints that are the point of failure - not the axels themselves. But it could be more cost effective to just replace the entire half-shaft assembly, which includes the CV joints on each end, rather than just replacing one or more CV joints. Maybe Ford only recommended that my service center replace the CV joints (not sure whether inner, outer, or both), or maybe the service center is just telling me they are replacing the cv joints when in reality they are replacing the entire half-shaft assembly on both sides. We'll have to share paperwork when all is said and done.

How to Tell if You Have a Bad CV Axle or Half Shaft (repairpal.com)

And by all means, point out any corrections to what I posted above because I am NOT a mechanic.

Not a correction, just a comment. It’s generally less expensive for a mechanic to get an entire half-shaft and replace it than to rebuild it by changing out the CV joints, especially in a production setting like a dealer. I know some old-timey boutique mechanics who will do the rebuild job themselves but they are the exception. ?‍?

 

[jrdelong1043]

All these comments are making we wonder why ford told my dealer to replace the motor. Not sure why they wouldn’t try the half shafts first. Apparently they checked out and ford said put a motor in it. I’m waiting for a rental car so I can take it in.

 

[Badger66]

Based on my half shafts being replaced and still having the rattle I think it's more suspension oriented... like something is making contact with a component when turning as there is no vibration.

 

[Mach-e4x]

Based on my half shafts being replaced and still having the rattle I think it's more suspension oriented... like something is making contact with a component when turning as there is no vibration.

I can't tell if the sound is coming from the left side while turning left or right side while turning right,
or from the same place. I might try placing a small digital audio recorder in the frunk to investigate.

 

[Maquis]

So as I read more about this, I can understand why there might be a little confusion between half-shafts and cv joints. We've got two half-shafts (aka axels) in the front of the car, one for the right wheel and one of the left (hence "half" shaft). Each half-shaft has a "constant velocity" (CV) joint on each end - the inner joint connects to (in our case) the electric motor, and the outer joint connects to the wheel.

It is typically the CV joints that are the point of failure - not the axels themselves. But it could be more cost effective to just replace the entire half-shaft assembly, which includes the CV joints on each end, rather than just replacing one or more CV joints. Maybe Ford only recommended that my service center replace the CV joints (not sure whether inner, outer, or both), or maybe the service center is just telling me they are replacing the cv joints when in reality they are replacing the entire half-shaft assembly on both sides. We'll have to share paperwork when all is said and done.

How to Tell if You Have a Bad CV Axle or Half Shaft (repairpal.com)

And by all means, point out any corrections to what I posted above because I am NOT a mechanic.

Small technical correction - the outer CV joint connects the axle half shaft to the spindle shaft, not the wheel.

 

[Badger66]

I can't tell if the sound is coming from the left side while turning left or right side while turning right,
or from the same place. I might try placing a small digital audio recorder in the frunk to investigate.

Mine appears to come from both sides.... almost like something it vibrating on the frunk tub.

 

[Nav]

Wow this is getting bigger, and still no clear solution yet. I'm happy we have this community for sharing info/knowledge.

could be more cost effective to just replace the entire half-shaft assembly, which includes the CV joints on each end

Thanks for clearing that up! I was going to ask about CV joints next but didn't know those were already part of it.

All these comments are making we wonder why ford told my dealer to replace the motor. Not sure why they wouldn’t try the half shafts first. Apparently they checked out and ford said put a motor in it. I’m waiting for a rental car so I can take it in.

LOL - I couldn't remember who it was, but was just wondering the same as I read through the latest posts here. Would be very interested in the outcome, keep us posted!

Based on my half shafts being replaced and still having the rattle I think it's more suspension oriented... like something is making contact with a component when turning as there is no vibration.

Maybe why they are going for the brake pads and rotors on mine next? I can't take it in till after xmas though. The sound did start out as a "clunk" for me, but I agree that during a turn it's more of a continuous rattle now as others are reporting. It took a longer, more sustained turn to realize this distinction. Some have talked about doing a figure 8 in a parking lot. That'll do it!

 

[Mach-e4x]

Mine appears to come from both sides.... almost like something it vibrating on the frunk tub.

I think the front motor has a cover to help insulate the noise so I have to wonder about that.

 

[Badger66]

Breaking news.... one of the owners I know has the exactly the same noise and has just had both half(drive) shafts replaced and ........ the noise is still there and not changed at all!
Thinking more suspension, brake components.

Someone said it almost sounds like something is tapping on the tub in the frunk when turning!

 

[methorian]

Breaking news.... one of the owners I know has the exactly the same noise and has just had both half(drive) shafts replaced and ........ the noise is still there and not changed at all!
Thinking more suspension, brake components.

Someone said it almost sounds like something is tapping on the tub in the frunk when turning!

I'm only one owner - but a front right half-shaft replacement fixed the noise for me, and the noise was similar to those videos posted on this thread so far.

My dealer diagnosed it using "chassis ears" to the front right - I think I posted my service write up somewhere on this thread.

Just letting folks know that it *might* be half-shaft, or might not be....

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