I met a new guy at work and he just left being a tech for the Ford dealership here, so I had him ride with me and try to diagnose the problem and he told me that the noise wasn't coming from the rear like the other tech thought. He said that when he put his ear to the floor of the truck he could hear the noise coming from under the truck in the area I the center console area. So he looked under the truck and noticed that the drive shaft was leaking and believes that it is where the noise is coming from.

So he'll I don't know I'm taking the truck into Ford in the morning and having them try to adjust the parking brake and check out the drive shaft and hopefully one will be the issue.

And unfortunately Ford engineering said that the scrapping noise is normal and could be louder in some vehicle and advised the dealer not to try anymore repairs on the brakes. Cough"bull ****"

 

"Normal" my a**.

 

Sorry to hear about the problems. If it were my truck, I'd put the rear axle up on jack stands and put it in gear and try to find the noise from outside the truck. While very dangerous, this is also a better way to find a noise than riding around in the truck.

Also, you've got lots of warranty left. Driving it for a while should allow the issue to either wear in, or get much worse. In either case you will be better off.

 

Ok so my truck is still making the same noise only louder I finally got the idea o putting a digital recorder under the truck and recorded the noise, because the mechanic said he never heard the noise last time. So I took the recording with me today when i took the truck in so they could replace the seal and the drive shaft flange. I'm hoping the recording will help them and they can figure out what's wrong with my truck and get it fixed. The F***ing noise is killing me!!!!!!!!!!

 

Just a theory have you tried bring it up to speed and putting it in neutral and coasting and seeing if the noise is still present?

Not a mechanic by any means but worth some shots? mabye..?

1- check diff fluid
2- See if it does it in reverse
3- ( possibly stupid ) jam the breaks a few times at speed see if it knocks loose
4- Check for stuff caught in center caps if you have them
5- Doubt it but loose fender support or something
6- See if it does it while turning ( weight shifted on one side )

Just saying again i'm not a mechanic 18 only actually, never know about something I search for a clunk for weeks on my old truck to bump the mudflap and notice its loose

 

The pictures are troubling to me, note that the shinny part is shinny because it is being rubbed by the seal as it slips in and out of the xfer case. I'll look at mine but that looks like a hell of a lot of movement and I dont think it is typical. It make me wonder how much spline to spline is contacting sticking out that much and if it isnt much then you could be chewing up your splines which can cause noise and would only happen while it is moving/turning. Also, like 1 other mentioned, put it on rear stands and block the front tight. With the engine off and in neutral rotate the wheels with your hands and see if you hear it. If not put it in park and move jerk the rear wheel back and forth till it engages and see if you hear any slop/banging that sounds like the issue you are hearing. PS, I am a mechanic but an Aircraft 1, lol

 

You did state that your brakes were "torn up" with 1,800 on the odometer. Did they check your brake lines? There may be a slight blockage in the line or at the connector- just enough where the fluid gets in but can not exit quickly enough. All it takes is a little contamination. Just a thought.

 

Do you have an after market exhaust system on it? I had a noise similar to that but it was coming from where the resonator and the pipe that comes down from the cats connect. It was slightly misaligned, causing metal to scrape on metal ever so slightly, but the noise was there to bother you. I got under there, loosened the screws, straightened it as best as I could, retightened the screws, and I was good to go.

 

Ok so went to pick up my truck last night the service writer told me that they replaced the parts and the noise was gone. He stated that he had two of his guys take it for a road test and they could not hear the noise. I get in and what do you know the noise is still there. F**k! Oh and now my transmission has a big clunk when it downshifts and this never happened before taking it in. I will have to try some of your suggestions and see if that works. Also I still have stock exhaust.

 

I know you are on an island, but is there another dealer available?