clunking/small knocking when light braking

[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.

@Xiaoqian thx man!!! I can conform the fix today 200% I removed the output flange today and indeed not one bit of grease mine looked the same build in januari 2024. I even had some play on the splines after cleaning and put ceramic grease on the splines retorque everything no more play! And guess what first drive today without clunck only the exhaust! Going to order a New one too just to be safe because of the play on the splines. I will post some photo's of the proces after the New part arrives because i could clearly see where the wear was. Thx man!

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[GID33Yup]

Mine goes to the shop tomorrow. They will be replacing the Output Shaft Flange, as stated above. Hope this resolves my clunking issue... Finger crossed.

 

[Cobrakit]

Is there a recall or a TSB out on this issue? My DH A10 makes a clunk noise when baking up, then braking.

 

[GID33Yup]

Took my DH to the dealer this morning. The Output Shaft Flange is on back order. I had them remove the old one and it was bone dry, no grease. Service tech applied grease to the external splines coming from the trans and also greased the splines on the inside of the Output Shaft Flange. Took the car for a test drive and no clunking or popping noise. This seems to have fixed the issue, but I will continue to drive it and see if the noise returns.

 

[Adautomotive]

Is there a recall or a TSB out on this issue? My DH A10 makes a clunk noise when baking up, then braking.

There is no offi

Took my DH to the dealer this morning. The Output Shaft Flange is on back order. I had them remove the old one and it was bone dry, no grease. Service tech applied grease to the external splines coming from the trans and also greased the splines on the inside of the Output Shaft Flange. Took the car for a test drive and no clunking or popping noise. This seems to have fixed the issue, but I will continue to drive it and see if the noise returns.

Told ya had the same!

 

[Cobrakit]

There is no offi

Told ya had the same!

Do you have the part number?

 

[Adautomotive]

Do you have the part number?

Do you have the part number?

I Will post the parts tomorrow when in the shop.

 

[GID33Yup]

There is no offi


Told ya had the same!

Crazy how a little bit of grease makes a huge difference. I've only driven it 25 miles since they applied grease. I'll know more after this weekend. It's not my daily.

@Xiaoqian - Thanks for your diagnosis and input much appreciated!

 

[Adautomotive]

Crazy how a little bit of grease makes a huge difference. I've only driven it 25 miles since they applied grease. I'll know more after this weekend. It's not my daily.

@Xiaoqian - Thanks for your diagnosis and input much appreciated!

Keep us informed here the same not the daily but last drive it was perfect.
There is like another tsb from Ford with the "clicking noise" when shift from D to R a complete other noise ofcourse but the fix from Ford is replace halfshafts and bearings and it's the same grease between half shaft and bearing contact face and no more clicking sound this one i already knew because we have a lot of audi and bmw and the had the same problem and fix.

 

[Cobrakit]

I've been trying to get info about any related TSB for output shaft or P/N to no avail. Anybody have a possible TSB or P/N? As we all know, going to a dealer unarmed can be frustrating.

 

[Adautomotive]

I've been trying to get info about any related TSB for output shaft or P/N to no avail. Anybody have a possible TSB or P/N? As we all know, going to a dealer unarmed can be frustrating.

 

[Cobrakit]

Thanks!

Looks like that number translates to : JL1Z-7089-B.

 

[Adautomotive]

Thanks!

Looks like that number translates to : JL1Z-7089-B.

These are the oem numbers from my vin nr i also noticed they use all New part numbers and eventually a lot of parts are used on a model before for example the front stabilisator bars are New numbers and the are the same ass on a s550 this flange the same it's evantualy just a 10r80 gearbox. Maybe good to noticed i am based in europe so the numbers are different then in usa to 5years ago it was hell for us to find the correct parts now it's finally getting better.

 

[GID33Yup]

I've put about 200 miles on the DH since the grease was applied and haven't heard the clunk/pop. I'm still waiting on a new Output Shaft Flange to arrive at the dealer. It's currently on backorder. Once it arrives I will have them remove the original and replace with the new one. We will also check and see how much grease is still in there.

I'm considering taking a pair of calipers to measure the major and minor diameters on the spline shaft and output shaft flange. I'll compare the spline dimensions on the original flange and the new one to see if the fit is tighter than OEM.

 

[Cobrakit]

I've put about 200 miles on the DH since the grease was applied and haven't heard the clunk/pop. I'm still waiting on a new Output Shaft Flange to arrive at the dealer.

I'm trying to nail down the source of the noise myself before going to dealer. Does yours sound likes it's coming from back of car ? Mine makes sound repeatedly when backing up and braking, then going forward. Keep us informed on grease, dimensions and parts replaced.

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