clunking/small knocking when light braking

[Will2]

For the benefit of anyone who stumbles upon this thread in the future: there are 2 different issues described in this thread.

Most posters are referring to 'transmission output shaft flange' lacking lubrication, causing a driveline clunk at low speeds or shifting between Drive <> Reverse). My 2025 Mustang had this, and TSB 20-2253 (technically for 2018-2020 Expeditions/Navigators) fixed it: https://static.nhtsa.gov/odi/tsbs/2020/MC-10179116-0001.pdf. Basically the same fix Xiaoqian and other posters wrote about. I noticed it most on 3-->1 downshifts rolling to a stop (10R80), just before full stop ~3mph.

The 2nd issue described in this thread is SSM 52444 (supercedes SSM 52428), clicking/pinging from a rear wheel when just starting to roll, or between forward/reverse directions. My 2024 Mustang had this, and it dates back to S550s (Ford still hasn't solved it?!). The SSM (Ford's version of a TSB-lite) is here: https://static.nhtsa.gov/odi/tsbs/2024/MC-10253687-0001.pdf
Ford procedure is to replace half-shaft + wheel hub, but the best video I found is a Ford mechanic describing the root cause (on 2020+ Explorers), where he explains his theory and fix without necessarily replacing those parts (5:00min mark):
2020 and Up Ford Explorer Ting Pop Fix - When put in Reverse and Drive Makes And Metalic Ting - YouTube
On S550 Mustangs there was the same/similar "thrust washer" issue, and many people replaced/removed them, but I think S650s may not have thrust washers anymore (like what the video mentions for Explorer generations too). If it's in-warranty, I'd just bring it to Ford for SSM 52444.

These are systemic issues across multiple Ford models/generations. Really wish we could buy a Ford built right from the factory, so we don't have to play diagnostic detective and re-do their work.

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[D/\rK•650]

I forgot to ask you did you hear scratching comes from that side? Regards to the scratching marks on your ring?

No have not heard any scratch type sound, just the clunk, I also have a vibration in my floorboard when suspension uncompresses but im not sure if it's related. Don't think it there's any marks on inside of rim.

 

[D/\rK•650]

Update:
It's been 6 months since the dealer applied grease to the output flange and splines.
I currently have 6500 miles on the car and it's running great. The popping/clunking noise has not returned.

Hello, just to verify did they replace the output shaft? Do you plan on having them do that if not? Otherwise no issues or returning clunk just from grease only? They put grease on mine but I dont have car back yet. They did verify the clunk though so thats good.

 

[D/\rK•650]

Im wondering if mine was worn enough to have to have it replaced but I won't know till more miles i put on after grease only fix applied. Mine did not start clunk till 5500 or 6000 miles. Will report on exactly what they did when car is home.

 

[D/\rK•650]

The vibration in the floorboard could not be duplicated, but I had i feeling that would be the case. Its not an earth shattering vibration it's minimal and only extremely brief when suspension is top or near top of its stroke. Also it's harder to notice if your left foot is not by the seat flat on floor like I usually have it. Maybe im just to sensitive or something or looking to hard at every little thing. Might all mustangs do that but people dont even feel it. Maybe a combination of the handling pack stiffer drive and wider low profile tires, or maybe im just trying to talk myself into just letting it go even if it's not normal. Sorry to rant just had to get that thought stream out.

 

[Xiaoqian]

Hello, just to verify did they replace the output shaft? Do you plan on having them do that if not? Otherwise no issues or returning clunk just from grease only? They put grease on mine but I dont have car back yet. They did verify the clunk though so thats good.

You only need to replace the output shaft flange, which is the part connected to the shaft. Remember to ask them to put enough grease on both sides of the anti-ting ring, which is a piece of metal coming together with the flange part if the dealer is going to order it for you. Then the problem will be solved if your clunck is the same with ours.

 

[D/\rK•650]

You only need to replace the output shaft flange, which is the part connected to the shaft. Remember to ask them to put enough grease on both sides of the anti-ting ring, which is a piece of metal coming together with the flange part if the dealer is going to order it for you. Then the problem will be solved if your clunck is the same with ours.

Mine was greased only and it haven't driven enough to verify it's completely gone. Will report back after more seat time.

 

[Cobrakit]

Remember to ask them to put enough grease on both sides of the anti-ting ring, which is a piece of metal coming together with the flange part if the dealer is going to order it for you.

Anti-ting ring ? Picture?

 

[D/\rK•650]

I wonder what the anti-tinq ring does look like? Probably looks like a big slim washer maybe??

 

[Will2]

Anti-ting ring ? Picture?

I wonder what the anti-tinq ring does look like? Probably looks like a big slim washer maybe??

Page 3 here shows what proper grease on the anti-ting ring looks like
https://static.nhtsa.gov/odi/tsbs/2020/MC-10179116-0001.pdf

(This is the TSB for Expeditions/Navigators but it's actually the same issue)

 

[D/\rK•650]

Can someone tell me how the quote+ works? It says added to multi quote?

 

[D/\rK•650]

Will2 thank you for posting the PDF.

 

[Xiaoqian]

Anti-ting ring ? Picture?

 

[D/\rK•650]

So been driving now for a bit and all seems fine. Clunk no longer, Im cautiously optimistic.

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