Rear End Clunk

[SimonXR6Turbo]

Having problems with your FG Falcon? It won't be the first time, nor the last.

There is a known issue with the diff bushes. This can cause a clunking sound. I experience it cornering at slow speeds, or reversing.

Ford technicians have personally told me that the bushes crack/split after a year or two. Replacement OE bushes from Ford last about the same. Fords attitude seems to be wait till outa warranty, then not our problem...

One of the concerns for the future is that because the cars tailshaft is dynamically balanced to the car (I.e. on the car, rather than off it), the looseness in the bushs/mountings, and the force of the repetetive clunking can result in the car being in a state that is now out of balance, which could cause other problems in suspension, uni joints, pinion, drive shafts, tailshaft and potentially the trans, one would reasonably assume.

There is a solution, although Ford will not fit bushes which resolve the issue, under warranty....

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Nolathane Product Update 0920:

"Clunk, clunk - sound familiar"

Falcon BA-FG/Territory SX-SY models differential solution.

http://www.nolathane.com.au/bulletins/Update%20-%200920%20-%20Ford%20Falcon-territory%20diff%20solutions.pdf

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My car has been in three times now, each time apparently "fixed". Ford fixed must have a different meaning for "fixed" from that found in a dictionary.

1st time - replace diff bush (with same type that cracked in first place - genuine ford bushes known to be over compliant or to delaminate or split)

2nd time - tightened the suspension

3rd time - replaced rhr drive shaft in the FG's diff, which is manufactured by Dana

But every time on the drive home - that bloody knock again. The problem isn't fixed. They say it's fixed. They don't think it frustrating that I have to keep bringing it in, in the hope of having it resolved, only to drive away with the same diff clunk.

Other forum members have posted similar issues, but having either the diff or the tailshaft replaced - but the clunk hasn't gone away!

Ford obviously aren't going to fix it - although the staff appear friendly and helpful, they fail to rectify the issue and falsely claim the vehicle is "all OK".

But its not OK. It's the last Ford I will ever own. Anyone want a 2008 Silver 6spd auto XR6Turbo?

I suggest a class action, as from reading other posts I know others are pursuing litigation and suing Ford. Customer Relations Centre (CRC) is an oxymoron - they just refer you back to the dealer - not the most fun merry-go-round...

It's a known parts issue with potential safety implications, and can cause further problems with connected drivetrain/suspension components...out of warranty that's big bucks for me and other Ford owners. It's not like its a budget car - $50K when new.

Come on Ford. Without your customers (including us on the forum), you don't have a business!!

Department of Consumer Protection

Disputes and complaints - Consumer Protection - Department of Commerce

[Rudiger]

A good write up Simon and a subject you are obviously passionate about.

But welcome to the club mate.

I had a BA NA XR6 that had clunk in the driveline and then another in the left hand rear axle. 5 times I complained about it. 5 times they couldn't find the issue. I took it in with 105,000 on the clock (out of warranty) and they tell me it needs a new diff and tail shafts and it will cost a heap. I stuff them by saying it has extended warranty. they say, "Oh, does it, oh well, you dont REALLY need to put new stuff in".

I responded by selling the car and getting a Turbo. I have modded it and they (Ford) tell me they will cover this and wont cover that. Oh well. I'd rather have my car than really be worried about what warranty I'm voiding.

I agree that something should be done, but most, if not all, are just of the opinion that Ford service and warranty sux. Once you have experienced it, you tend to agree. Come up with a solution and ill jump on board, but my car is so far out of warranty with 75,000 on the dial and a bucket of mods, I'm beyond their scope anyhow.

Good luck.

Edited 02/08/10 04:41 PM by Rudiger

[Full Monty]

This issue has been talked about for eons in here.

Give Pat a call at wholesale suspensions and purchase a Super Pro, Polyurethane diff bush. Then Forget about it, it will outlive your car!