2006 F150 FX4 Supercrew 5.4 3v Flex:
About Every other day a loud rattling clanking noise comes & go's, first sounded like it was coming from my transfer case or where cat exhaust cross pipes meet. removed skid plate & brought to muffler shop they put it up and tack welded the cross pipe to the clamp then told me i had a blown catalytic converter & the pieces were rattling around in pipe. but he did not get to hear the noise (of course). left & came home and got under for further investigating & found the hose to the Transfer Case like this. got dark so I pushed it back over nipple and the End of hose is Hard & has Split about 1". where does the other end of this hose go? And would this cause it to Rattle or grind inside? I am not engaging 4wd when i hear this.Any input is appreciated.

 

Well I found out its Tranny Fluid spewing out of my Transfer Case Breather Tube because the seal between the two went bad

 

i have something similar happining feel grinding, cackling, noise like trying to go into 4 wheel dr this we though was 4x4 transfer case electric motor or switch but unhooked it and found it still happened has yours stoped or what did you do to stop it hope to help and get help! thanks

 

I have a 4x2 xlt that suddenly made a loud metal clunking noise(like I just ran over a metal object) when my truck was slowing down after another vehicle. It sounded so loud that I had to stop and jump out and inspect what I had hit, but there was nothing. It only happens on hour drives. Especially when my truck is slowing down with little brake applied. Would appreciate what to check, hope its not the tranny.

 

I am sorry to hear that your are one of many running into this problem. My buddy is a service manger that works at a Ford Dealership and he told me a list of things that the F-150 owner come in with.

Yea I have heard of this. It has to do with the grease pack that in the sleeve of the transmission shaft that oscillates back and forth when the vehicle is driven. There is rubber gasket/sleeve there and that is connected to you engine. In that gasket/sleeve the grease wares out and sounds so loud that you feel like your teeth are about to get kicked out. If you take it to the dealership they will fix it for free. They will cut away the gasket/sleeve and pack in a higher viscosity grease and replace the gasket/sleeve. That's the repair. I hope this helps.

 

Problem resoved Worn/distorted front discs...removed and machined-sanded pads and test drove....OK. Help from a this is what he wanted me say about him "Poor old machinist(ugly guy) without a razor...lol.