clunking/small knocking when light braking

[Ford Motor Company]

Hello. My Dark Horse is making the same noise. The dealer just replaced the half shaft sub assembly but that did not solve the issue. Help!

Hi there! Will you send us a message with your VIN and your local Ford dealer? I can look into things on my end.

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[LCFR]

Brother I get it, I’ve been suffering with this since February the car already spent more than 2 months at dealers, half of the whole thing got replaced and the list keeps building and they keep saying it is normal and there is nothing wrong with it. I am just like you don’t know what to do and regret every dollar of the purchase.

 

[JoeyD]

Hi there! Will you send us a message with your VIN and your local Ford dealer? I can look into things on my end.

Hello. I sent the information in a private message. Please confirm that you received. Thanks.

 

[Newdeath2]

Good day everyone from sunny Dubai, UAE. I have received my Ford S650 Dark Horse this month and have the same sound that was described in this thread, the car is 2024 GCC spec.

 

[5.DREW]

I have the same isssue with my Dark Horse. It almost feels like when I slow down and the trans downshifts to 2nd (auto trans). Also can't tell what side of the car. Sometimes it sounds like the right front and others the left. Actually from my mechanical experience, it sounds like a bad tranny mount

I find when I have mine In “M” mode and leave it in 3rd when I slow down the noise isn’t there which makes me think it’s a transmission or differential issue, my dealer has replaced the half shafts and hubs and the driveshaft and it’s still there

 

[Newdeath2]

Found one of us on YouTube with some new evidence of where the sound is:

 

[Tomrich]

Hopefully there will be a fix soon for the clunking noises everyone is hearing! I'm just tired of hearing it!

 

[Lastoutlaw_21]

Anyone getting getting a noise in reverse? I have a few friends with the 10 speed in their bronco, expedition, mustang, and truck and they are all getting noises when backing up in reverse. I use get a loud clunk noise when going into reverse but that was the brakes. I'm getting a shop to check some stuff out when I put the half shafts upgrades in.

 

[The Ghost]

Is this only happening on automatics? My car isn't a Dark Horse but it's a manual, and every once in a while I feel like I hear something similar to this when I clutch in and break. But it's like a singular clunk and not very loud.

 

[Newdeath2]

Is this only happening on automatics? My car isn't a Dark Horse but it's a manual, and every once in a while I feel like I hear something similar to this when I clutch in and break. But it's like a singular clunk and not very loud.

It seems to be the case, yes

 

[GID33Yup]

Same problem here.

 

[Newdeath2]

Hello everyone, Dark Horse owner from Dubai here. I have a Dark Horse that has a similar noise as the one described in this thread. A few thing I can add to the conversation are that I have a good idea on where the noise is coming from. Firstly I noticed that my noise also happens during light breaking/downshifts/Switching to R after D so this leads me to believe that it is related to the service bulletin Ford had for the previous Mustang. I will be going to my local dealer soon to talk to them about it but I am pretty sure that it's the one I think it is. Hope this helps someone in the future.

 

[CoolMonkey]

Did you talk to them? I’m part of the clunk club too

 

[Xiaoqian]

I’m a DarkHorse owner from China. Mine was built in Dec. 2023 and I bought it in June this year. I had the same issue at about 1,000 miles. I could hear the clunking noise when braking and then accelerating, and also when shifting from D to R. I could hear it from the driver's side and the passenger side and the back seat, as well. I took it to the dealer and they replaced a driveshaft for me but it still existed. So I went back to the dealer and they had 4 mechanics coming over to test drive it for 3 days, and eventually they found the problem: it wasn’t the driveshaft and wasn’t the half shaft either. It was the part that connects the transmission and the driveshaft that was making the noise. The part is called the output shaft flange.The old one was rusty and there wasn’t any grease in it. At first the dealer put some grease in the old one and put it back. I could hear much less noise, but it was still there, I could still hear it occasionally, like once in every 100 kliometers. Then I asked them to replace a new one for me, and the noise was completely gone! It's been a month and a half and 3,000 km since it was replaced and I haven't heard a single noise again. When replacing, do make sure they put enough grease in the flange and on both sides of the ring. The grease my dealer used is made in Japan by the way. It can endure a temperature range from -40 to 1400 degrees celcius. It won’t take long for them to fix it. I’ve attached a photo. The flange is the one in the red circle. You can see how rusty it was.

 

[Adautomotive]

I’m a DarkHorse owner from China. Mine was built in Dec. 2023 and I bought it in June this year. I had the same issue at about 1,000 miles. I could hear the clunking noise when braking and then accelerating, and also when shifting from D to R. I could hear it from the driver's side and the passenger side and the back seat, as well. I took it to the dealer and they replaced a driveshaft for me but it still existed. So I went back to the dealer and they had 4 mechanics coming over to test drive it for 3 days, and eventually they found the problem: it wasn’t the driveshaft and wasn’t the half shaft either. It was the part that connects the transmission and the driveshaft that was making the noise. The part is called the output shaft flange.The old one was rusty and there wasn’t any grease in it. At first the dealer put some grease in the old one and put it back. I could hear much less noise, but it was still there, I could still hear it occasionally, like once in every 100 kliometers. Then I asked them to replace a new one for me, and the noise was completely gone! It's been a month and a half and 3,000 km since it was replaced and I haven't heard a single noise again. When replacing, do make sure they put enough grease in the flange and on both sides of the ring. The grease my dealer used is made in Japan by the way. It can endure a temperature range from -40 to 1400 degrees celcius. It won’t take long for them to fix it. I’ve attached a photo. The flange is the one in the red circle. You can see how rusty it was.

Was there any play (movement) on it? Because inside it's bolted with a nut so i am curieus whats cousing the knock i have the same problem and for me it's less after transmission update. Just when i go from D To R i can here it and just like you explained sometimes it's like in the back sometimes front passenger side it's strange and irritating.

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