Axle clunk

[Maquis]

Mid-January built here. VIN was in the 6000's for me. I think for actual customer cars the last four of the VINs started with a 5000s # iirc.

Mine was a January customer order in the 8300s. I corrected my earlier post.

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[Benny’66]

So because the other companies products are defective it’s ok to make an inferior product also?

it’s the computer software syndrome, they throw stuff out and we end up testing for them by reporting problems and they fix on the fly.

I would think when they get something from a contractor they check it out first. Do extensive testing. People have been reporting this on the MME since April. My feeling is that Ford knew about it from day 1 but said, to hell with it, we are not going to hold up production, we will deal with it later , basically saying FU to customers

I am retired and have the time to bring in for service but when I was working I would not. To boot does ford give a loaner whenever there is a problem?, not all the time. Maybe they should pay us for doing quality review on their products. Some people have taken their cars in several times to no avail Waste of time and cost people money.

I would have loved to tell my clients when we made a mistake, well you know the other guy probably would have made a mistake also, or we are just practicing on your work.

believe it or not I am pretty mellow when stuff happens but not this, added to their complete lack of communication to their customers as to why cars are held up or why cars made in January are being shipped before cars made in OCt, Nov or December

Ford is not the only auto company that does this but they should do better. Hopefully if ever get my car I will not have issues but if I do ford will have lost me forever. First American car in 30 years and hopefully not a mistake.

this car hits all the right buttons for me and hopefully it works out OK

Wow, you have never worked in manufacturing from the sounds of your post. You do realize that many things in cars are made by humans still right? Take it from someone who worked in engineering and management for 2 of the Big 3 US automakers, humans can make mistakes even with the best training, work instructions, Poka-yoke, etc. And I would challenge anyone who hasn’t built hundred of planetary gear sets in a shift to do it before passing judgement.
It is possible that the Clunk, Clunk, Clunk the other poster was hearing while turning has more to do with a one-off miss-built component part in the gearbox then a deliberate act by the auto manufacturer to produce an inferior product.
We are all human after all. And I can assure you, when the root cause of this issue is determined, some engineer somewhere will get the assignments to implement a permanent corrective action so that this failure mode never happens again. And it will get added to a PFMEA with the appropriate RPN #, which based on your comments will help to increase the Severity ranking from a 2 to maybe a 5. So good job on that!

 

[Ixoye]

is this happening to early production cars or even later ones. Getting me nervous.

Mine is a FE so I am assuming it was an early production car.

 

[kennethjk]

Wow, you have never worked in manufacturing from the sounds of your post. You do realize that many things in cars are made by humans still right? Take it from someone who worked in engineering and management for 2 of the Big 3 US automakers, humans can make mistakes even with the best training, work instructions, Poka-yoke, etc. And I would challenge anyone who hasn’t built hundred of planetary gear sets in a shift to do it before passing judgement.
It is possible that the Clunk, Clunk, Clunk the other poster was hearing while turning has more to do with a one-off miss-built component part in the gearbox then a deliberate act by the auto manufacturer to produce an inferior product.
We are all human after all. And I can assure you, when the root cause of this issue is determined, some engineer somewhere will get the assignments to implement a permanent corrective action so that this failure mode never happens again. And it will get added to a PFMEA with the appropriate RPN #, which based on your comments will help to increase the Severity ranking from a 2 to maybe a 5. So good job on that!

Nope, I have never worked in manufacturing but have worked with manufacturing companies. some are worse than others.

You say you have worked for 2 of the 3 us car company’s. They don’t always have great track records which indicates a lot of something for sure.

test drive a car 1k miles you may not find any issues. Test drive it 5 million miles you find many more issues.

I would love to know the testing that occurred with the bolt. The recommendation now is not to park the car in the garage, gives me such a warm and fuzzy feeling. GM has had many issues over the years of complete disasters. Diesels are another one that comes to mind.

why do some manufacturing companies have better track records than others. I get it that cars are complicated beasts and many things can go wrong but I also know corporate America and to think that they didn’t know it’s an issue and “think let’s get the car out and deal with it later” is a mistake. Maybe they didn’t know and maybe they did. Guess we might never know.

windshield, sunroof, brake issues, PAAk barely working for some, this clunking noise, 12V battery issues, software issues, seatbelt recall. They have work to do or maybe they have fixed all.

in any event I don’t give them slack and none of us should. As consumers who spend 60k on a car we deserve better. If we don’t hold their feet to the fire they won’t get improve.

I bought a car at the end of the first year and expect it to have solved its issues or at least 99% of them. I have bough numerous first year cars, at the end of the first year and have not regretted it once.

hopefully I don’t regret this.

 

[Mirak]

Just one data point, but my First Edition has been running noise-free for about a month now since both the left and right CV assemblies were replaced (meaning the half shafts and the CV joints).

Also, I’m pretty sure there are at least two totally different issues being discussed in this thread. The CV problem results in a rapid hollow clicking noise from below the front of the car, like gravel knocking in the wheel wells. You’ll typically only hear it on sharp turns.

This “thunk” some people are speaking of doesn’t sound like the same thing.

 

[Nav]

Just one data point, but my First Edition has been running noise-free for about a month now since both the left and right CV assemblies were replaced (meaning the half shafts and the CV joints).

Also, I’m pretty sure there are at least two totally different issues being discussed in this thread. The CV problem results in a rapid hollow clicking noise from below the front of the car, like gravel knocking in the wheel wells. You’ll typically only hear it on sharp turns.

This “thunk” some people are speaking of doesn’t sound like the same thing.

That's great to hear, thanks! I would say "knock on wood" it continues to stay that way, but somehow that expression may not be the best here. ?

I hear you about there may be two different issues folks are experiencing in this same thread. Mine is the hollow, sustained type of noise during a turn. Sometimes as short as a few knocks, other times sounds like a handful of em coming from either the wheel well or in front of my feet. Now I just wish they had got on ordering the other half shaft back in December instead of going after the brakes and wasting a month.

 

[Cabel]

Just one data point, but my First Edition has been running noise-free for about a month now since both the left and right CV assemblies were replaced (meaning the half shafts and the CV joints).

Also, I’m pretty sure there are at least two totally different issues being discussed in this thread. The CV problem results in a rapid hollow clicking noise from below the front of the car, like gravel knocking in the wheel wells. You’ll typically only hear it on sharp turns.

This “thunk” some people are speaking of doesn’t sound like the same thing.

Mirak,

After watching some of the videos posted on this forum with the CV "clicking" sound, what my car does ("Klunk..klunk..Bang...")is definitely coming from the front differential. It is almost exactly like a limited slip that has worn out clutches or no friction modifier in the lubricant.

 

[Benny’66]

Nope, I have never worked in manufacturing but have worked with manufacturing companies. some are worse than others.

You say you have worked for 2 of the 3 us car company’s. They don’t always have great track records which indicates a lot of something for sure.

test drive a car 1k miles you may not find any issues. Test drive it 5 million miles you find many more issues.

I would love to know the testing that occurred with the bolt. The recommendation now is not to park the car in the garage, gives me such a warm and fuzzy feeling. GM has had many issues over the years of complete disasters. Diesels are another one that comes to mind.

why do some manufacturing companies have better track records than others. I get it that cars are complicated beasts and many things can go wrong but I also know corporate America and to think that they didn’t know it’s an issue and “think let’s get the car out and deal with it later” is a mistake. Maybe they didn’t know and maybe they did. Guess we might never know.

windshield, sunroof, brake issues, PAAk barely working for some, this clunking noise, 12V battery issues, software issues, seatbelt recall. They have work to do or maybe they have fixed all.

in any event I don’t give them slack and none of us should. As consumers who spend 60k on a car we deserve better. If we don’t hold their feet to the fire they won’t get improve.

I bought a car at the end of the first year and expect it to have solved its issues or at least 99% of them. I have bough numerous first year cars, at the end of the first year and have not regretted it once.

hopefully I don’t regret this.

I’m not sure what you mean by the domestics not having a great track record? Maybe you would believe the ultimate authority on initial quality JD Power then and I quote “Give it up for the local talent. J.D. Power has released its annual Initial Quality Study for 2020, and numerous domestic automakers have surged ahead this year. No less than half of the top 10 manufacturers are American, and one ties for the top spot overall.”
Having “worked with manufacturing companies” is like playing a doctor on TV. If you still have access to any of these companies, ask about their process capability metrics. Because ALL manufacturers are producing products to quality standard that the customer is willing to pay for. NO customer is willing to pay for 100% perfect quality in any product. So if my plant produces screws with 99.99% perfect quality, that sounds pretty darn good (and experts would agree at a CpK around 1.4 or 100 defect per million). And if you were the guy who just bought a box of screws for $10, but had to throw out 1 or 2 of those defect screws you really wouldn’t care cuz they are only a few pennies. But if you are a car manufacturer who makes, say the #1 selling truck in the US, at a million a year and the same 99.99% perfect quality, 100 consumer just paid $60,000 on those trucks so they have more of a right to be pissed off? See, as the owner of the screw manufacturing plant, I could hire qualified inspectors and testers at $25/hr to verify every screw is perfect, but are people willing to pay 4x or $40 a box for the same screw? The answer is NO Way! They will buy the competitors screws at $10 and throw some out or go back to HomeDepot for replacements. The same is true for cars and trucks. People will not pay $200,000 for a truck even if all 1,000,000 are guaranteed to be perfect for 3yr/36k miles. Nope, those 100 people will take those trucks to the dealer and have what ever defect repaired.
Since you are retired, I will assume you remember the days when MOST new cars went back to the dealer for “adjustments”. It was just expected and accepted. Having worked in the auto industry through the 90s and 2000s, I’m proud of the massive quality improvements that were made during those decades. To the extend that perfect quality expectations is now the norm and the benchmark. Amazing!!

 

[Diamond78]

Just had my left half shaft replaced…did NOT solve the noise issue. Next step would be the wheel motor?? How long before dealerships are made aware of this issue and/or Ford issues guidance? @Ford Motor Company

 

[Nav]

Just had my left half shaft replaced…did NOT solve the noise issue. Next step would be the wheel motor?? How long before dealerships are made aware of this issue and/or Ford issues guidance? @Ford Motor Company

ouch! sorry to hear that ?
Do you hear the noise when turning in one particular direction, or both?

Might be the other "noise" that some have mentioned here, and @Mirak alluded to. One is being resolved with half shafts, the other MIGHT be a front motor replacement? No success stories reported on the latter that I know of... yet.

 

[backwardsfish]

(anyone who has owned or been around a 1980's Audi or Honda can identify the sound of a bad CV joint)!

Hahaaaaa YES! My civic had that!

 

[Cabel]

Just had my left half shaft replaced…did NOT solve the noise issue. Next step would be the wheel motor?? How long before dealerships are made aware of this issue and/or Ford issues guidance? @Ford Motor Company

Diamond78, is your noise a light "click.click.click" that you hear, or a "THUNK.KLUNK.BANG" that you FEEL? The first light noise is typically CV joints, the second (like mine) could be an issue with the differential within the front motor. I believe the front differential has a light duty "limited slip" function. This type of differential uses clutch discs, plates or a friction cone to provide a bit of drag between the left and right wheels, along with ABS and computer controls, as part of the traction control system. I think what is happening (at least in mine) is that in very cold weather something is sticking. It releases ("BANG!!") on sharp turns at low speed.
I have a ticket open with Ford Customer Care and will be taking it in to my local dealer to have it looked at. It could be as simple as a calibration with the traction control, a change of lubricant, or as severe as replacement of the front motor. I'll let the forum know when I find out. No word from Ford yet on when to take it in but their last message to me was last night, so I have hopes I'll be getting it checked out soon.

 

[msherman1]

Just had my left half shaft replaced…did NOT solve the noise issue. Next step would be the wheel motor?? How long before dealerships are made aware of this issue and/or Ford issues guidance? @Ford Motor Company

I had my half shaft replaced as well and the car is still making the noise on the right and the left side. It only happens now when I make a sharp U turn.

 

[SpaceNeedle]

Dealer had my car for 3 days and said they could not hear the noise. I explained it was only on low speed sharp turns. They said they inspected the half shafts and they were fine. Picked it up late today and I could still hear it clearly . Not sure what to do next.

 

[cjljr41]

Dealer had my car for 3 days and said they could not hear the noise. I explained it was only on low speed sharp turns. They said they inspected the half shafts and they were fine. Picked it up late today and I could still hear it clearly . Not sure what to do next.

Perhaps you can replicate the noise in the dealership parking lot with the service manager in the car with you.

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