Driveshaft With a Thump or Clunk Condition

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Inspect the vehicle to see if the driveshaft and skid plate have been updated.

If the vehicle has not been updated, carry out the entire procedure.
If the vehicle has been updated with a 4.0 inch aluminum driveshaft, and the vehicle has a clunk on acceleration or when hitting a bump, only carry out the fuel tank relocation steps.

Fig 1: Identifying Driveshaft With A Thump Or Clunk Condition
Courtesy of FORD MOTOR CO.

CAUTION: If new driveshaft bolts are not available, coat the threads of the original bolts with threadlock and sealer.

NOTE: Inspect the driveshaft. If the vehicle has a 4.0 inch aluminum driveshaft, do not install another driveshaft.

Remove the 3.5 inch steel rear driveshaft and install a 4.0 inch aluminum rear driveshaft. This will require a revised fuel tank skid plate, if equipped.
- Index-mark the rear axle flange and transfer case flange to the yellow marks on the steel driveshaft. Remove the steel driveshaft. Using the index marks, align and install the new aluminum driveshaft.
Remove the fuel tank and the fuel tank skid plate. Refer to FUEL TANK & LINES .
Remove the existing gusset.

Install a new gusset, a new nut plate and new bolts.

ITEM DESCRIPTION

Item	Part Number	Description
1	2L54-5097-BA	Gusset
2	F87Z -5A074-AA	Nut plate
3	W705613-S436	Gusset-to-crossmember bolts
4	N803892-S60	Gusset-to-frame bolts

Torque the gusset-to-frame bolts to 90 N.m (66 lb-ft).
Hold the nut plate in place, then torque the gusset-to-crossmember bolts 40 N.m (30 lb-ft).

Install the fuel tank and the fuel tank skid plate. Refer to FUEL TANK & LINES .
Verify the condition has been corrected.