[DavidPJ]

As noted previously, my Escape's clunk noise was lessened. But it's still there. Since having the Escape at another dealer, my original dealer called me with a time for a Ford Field Engineer to review the matter. So he'll be looking at the Escape next week.

The Ford FSE will not meet with customers directly. I still have to go through the dealer's service manager. I can't wait to tell him about the leaking transmission that his service department didn't find.

I still find the noise unusual and I want Ford's direct response on the matter, and in writing. If this clunk noise is normal, then why did I not hear it on the Escape I drove on the lot recently? How come there's only one person on this board (SD-455) that also has experienced it?

I'll post again after the FSE looks at it.

[DavidPJ]

The Ford Field Service Engineer evaluated the clunk yesterday. His conclusion was that it was normal (no surprise). I wasn't allowed to speak with him directly, but the dealer rep told me that the noise comes from both axles and spline gears. He offered to put the Escape on a lift and show me at my next service visit.

I told them all about the other dealer and the low tranny fluid, torque converter leak, etc. I was told it was impossible to have had that oil leak and not have noticed oil on the ground. I was told that the clunk could not have been caused by the torque converter, even if the oil was low. The implication was that the work performed by the other dealer was probably not necessary and had nothing to do with clunk.

I asked what was it the other dealer could have done to reduce the clunk noise if it wasn't caused by low tranny fluid and they didn't have any idea. My dealer rep said there's nothing than can be done to reduce the noise, and of course, it's normal.

So in the end, this whole thing remains a mystery. Unless I believe the other dealer about the oil leak, low fluid and pressure, there's no other explanation for how the noise level of the clunk was reduced. Maybe simply changing the tranny fluid helped somewhat. I least now I have the problem well documented by the original dealer and a direct Ford representative.

[wptski]

Originally Posted by DavidPJ

The Ford Field Service Engineer evaluated the clunk yesterday. His conclusion was that it was normal (no surprise). I wasn't allowed to speak with him directly, but the dealer rep told me that the noise comes from both axles and spline gears. He offered to put the Escape on a lift and show me at my next service visit. I told them all about the other dealer and the low tranny fluid, torque converter leak, etc. I was told it was impossible to have had that oil leak and not have noticed oil on the ground. I was told that the clunk could not have been caused by the torque converter, even if the oil was low. The implication was that the work performed by the other dealer was probably not necessary and had nothing to do with clunk. I asked what was it the other dealer could have done to reduce the clunk noise if it wasn't caused by low tranny fluid and they didn't have any idea. My dealer rep said there's nothing than can be done to reduce the noise, and of course, it's normal. So in the end, this whole thing remains a mystery. Unless I believe the other dealer about the oil leak, low fluid and pressure, there's no other explanation for how the noise level of the clunk was reduced. Maybe simply changing the tranny fluid helped somewhat. I least now I have the problem well documented by the original dealer and a direct Ford representative.

So they are saying that the axle's spline is loose in the side gear's splined inside diameter?

I'm not sure how the axle spline is mated to the side gears. I did retire from Ford's Gear/Axle Plant or what was left of it. I do know for a fact that the spline on a pinion gear isn't rolled perfectly straight, so when the splined slip yoke goes over it, it actually binds and gets tighter. I worked more in the ring/pinion area than the axle area, so I'm not sure about the mate of the rear axle to the side gears. I know there is a retaining clip inserted from the inside.

I know that the Escape's transaxle half-shafts are removed using a slide hammer, so they have some sort-of retainer and/or are a tight fit. I'd think that they should be a friction fit. If you have a sloppy spline, it's just going to get worse over time.

Didn't you have a axle leak repaired? Did they replace the axle support bushing also?

[DavidPJ]

Thanks Bill. My Escape didn't have the half shaft leak so bushings were not replaced.

[DavidPJ]

Had my Escape in last Thursday and Friday for the 1/2 shaft leak. Dealer replaced the entire shaft for the fluid leak problem and now the clunk is gone (so far). I haven't driven it much but I noticed right away that the annoying clunk was gone. I can't tell you how happy I am about this and it looks like the half shaft leak was a blessing in disguise!
I can only hope the noise doesn't return.

[ATK]

I have a 2010 Ford Escape XLT, AWD, V6. I just took it in for a "clunk" noise on the front end (i think) that happens ocasionally. The dealer just called me back witht he "this is normal" according to our books; and that I should just here it once after start; which is not true.
Also, totally unrelated (will post in a separate forum), I can "feel" a sensation on the gas pedal when the powerdoor lock enables after a few feet of driving...was also told this is normal. Bottom line: I'm not convinced.

[DavidPJ]

ATK, I don't know if the clunk you're hearing is the same as in my post, but the clunk I described has long since returned. One dealer told me it was the locking of the torque converter that I was hearing and it was normal. I took it to a total of 3 dealers plus had a Ford field service engineer look at it and they all told me it was normal. I've since given up on it and it's just another thing I live with on this vehicle. I don't think it's normal but there doesn't appear to be anything I can do about it. If something finally breaks my extended warranty will hopefully cover it.