Dark Horse gone, but it's the dealer who's the lemon!

[danyoem]

I'm currently dealing with a dealer that says my car with a clunk coming from the right front is perfect.

My Dark Horse was delivered with a clunk from the right front, sometimes felt like it was in the center just in front of the firewall. It turned out to be the transport blocks that should have been removed by the selling dealer but never were. Cost me $460 to have another dealer remove them and recheck all front suspension fastener torque settings.

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[Dave_E]

I've got the clunking on downshifts and when sponge between drive and reverse. Im still not sure they need to replace the diff from what I've been reading on this forum. It sounds like it's more to do with the output flange.

Sounds like the output shaft flange for sure. It's well documented on here. It will get worse. If it clunks on pure decel it's that. Accelerate to 35 ish in 2nd and just let off throttle. 5 seconds later, clunk. I have youtube vids of mine doing it if you need...

There's tons of people on here who've had diffs, hubs and allsorts, but it's the flange. Not sure of the 'lemon' or buyback procedure in the UK (despite being from the UK ) I've only had to do it once and that was here in the US.

 

[LouG]

Do Ford dealers elsewhere do a free "peace of mind" check at around 2000 - 3000kms? Check fluid levels, retorqueing important bits, etc.
I was suprised when mine did, never had that on any new cars, did on bikes though.
It was a nice touch.

 

[LouJay99]

Sounds like the output shaft flange for sure. It's well documented on here. It will get worse. If it clunks on pure decel it's that. Accelerate to 35 ish in 2nd and just let off throttle. 5 seconds later, clunk. I have youtube vids of mine doing it if you need...

There's tons of people on here who've had diffs, hubs and allsorts, but it's the flange. Not sure of the 'lemon' or buyback procedure in the UK (despite being from the UK ) I've only had to do it once and that was here in the US.

If you have a vid, that would really help! The UK technicians seem to have no knowledge of the DH, so anything will help. If they can't fix in a reasonable time (it's been 6 weeks so far) then I'll refuse the car and ask for a new one of the same spec. I really don't want it to come to that mind. Im hoping the dealer i purchased it from has some sense and addresses the flange before replacing the diff.

Thanks again for your input

 

[Dave_E]

If you have a vid, that would really help!

There you go
Not sure how bad yours is yet, it does get progressively worse, but these were the sound of my flange right before it was replaced.
It got to the stage where any change between accel and decel would immediately clunk.
Good luck!

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