clunking/small knocking when light braking

[Adautomotive]

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.

@Cobrakit it was the same for me noise from rear right then i thought it was right front etc. The best to replicate the noise "for me" was turn the wheel to right

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.

I noticed the extensieve play without grease. If you remove the 15mm bolt and slide it over the spines and gently twist from left to right you feel it immidatly. When i removed it you could see in the back of the hub spline wear. The 15mm bolt came lose like it was just hand tight even there was red loctite on it. My opinion is when we put grease on it dampens the play plus when you put it back it goes not in the same splines wich eliminates the play further. Mine arrives today i Will take some pictures from the New and old one.

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[Xiaoqian]

@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!

My pleasure to help everyone in here. It was indeed very difficult to spot where the noise came from. Fortunately the mechanics helped me solve the problem and I would really like to share it with everyone in the world who has the same issue, because I know this car is pretty rare and I also know how irritating the noise can be.

 

[RaceRedder]

My pleasure to help everyone in here. It was indeed very difficult to spot where the noise came from. Fortunately the mechanics helped me solve the problem and I would really like to share it with everyone in the world who has the same issue, because I know this car is pretty rare and I also know how irritating the noise can be.

I'm not mechanical, but how difficult is it for a mechanic to change this part? How deep is it hidden in the car? Is it easy to reach?

 

[Adautomotive]

I'm not mechanical, but how difficult is it for a mechanic to change this part? How deep is it hidden in the car? Is it easy to reach?

Litteraly 15min job. 4 bolts driveshaft put driveshaft a little aside and one bolt from flange. And that's it. No heatshield or other parts need to be removed.

 

[Adautomotive]

I'm not mechanical, but how difficult is it for a mechanic to change this part? How deep is it hidden in the car? Is it easy to reach?

Litteraly 15min job. 4 bolts driveshaft put driveshaft a little aside and one bolt from flange. And that's it. No heatshield or other parts need to be removed.

 

[CoolMonkey]

Unfortunately it didn't fix my problem so the dealer is changing the driveshaft now. On the side note they broke my front splitter when they lifted the car...

 

[brandonxDH]

hello all, fellow 2024 mustang dark horse owner here. i have been dealing with this issue as well for about a month now. Took my car to a dealer 3 times and every single time they sent me back with the car not being fixed. The noise has been consistent and even when showing the techs there at the dealer they specifically told me, “If it gets worse bring it back.” ... Anyways, they claimed it was my lowering springs making the noise. Took them out and put back the stock ones, guess what? Still making the noise. I can say for the time it’s been doing this it has not effected performance at all. So i’m in a pickle of annoyance at the moment.



If anyone has figured this out please let me know, tired of dealing with these dealers.

 

[Adautomotive]

Unfortunately it didn't fix my problem so the dealer is changing the driveshaft now. On the side note they broke my front splitter when they lifted the car...

And what exactly didn't fix your problem?
They removed it? Put grease on? Replaced the flange? What did they do?

 

[Adautomotive]

And what exactly didn't fix your problem?
They removed it? Put grease on? Replaced the flange? What did they do?

If they damaged your front splitter while lifting it i wonder if they even know what flange it is. They lift it with a forklift???

 

[CoolMonkey]

And what exactly didn't fix your problem?
They removed it? Put grease on? Replaced the flange? What did they do?

They will try to replace the shaft. I will get some update on the 17th

 

[HMBSTNG]

Can someone share the torque specs? I just discovered this issue recently and want to try this out myself first. Thanks

 

[HMBSTNG]

Litteraly 15min job. 4 bolts driveshaft put driveshaft a little aside and one bolt from flange. And that's it. No heatshield or other parts need to be removed.

Do you have the torque specs? Also, after removing the driveshaft to the side, remove the single flange nut and it just slides out? Do I need a pulley removal tool?

Also, What socket size are needed?

Thank you so much!

 

[5.DREW]

I’ll be doing this to mine as well, please if anyone can provide the torque specs and what kind of grease to use I’d truly appreciate it

 

[HMBSTNG]

I’ll be doing this to mine as well, please if anyone can provide the torque specs and what kind of grease to use I’d truly appreciate it

All bolts are 81#. Make sure you use orange locktite

Used Valvoline Moly-Fortified Gray Full Synthetic Grease, 1 Pound. Got it from Advance Auto

 

[HMBSTNG]

One a side note; my issue wasn't even this. It end up being a bad wheel bearing passenger rear that was making that clunking sound. Ford warranty

Also, my shaft was bone dry. I lubed it with the above grease and nothing changed. I had ZERO play before and after.

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