Intermittent aluminum crunching/ shifting sound under driver side. Help!

[iam7foot1]

Hi all! '23 XLT Lightning SR owner for about a year now. About a month ago, I started hearing an intermittent sound once every 20-30 minutes coming from under the driver's side. The best I can describe the noise is like a loud aluminum soda can crunching. It sounds like aluminum is popping in and out of place. I took it to the dealer and they thought it might be the wheel bearing. They replaced the wheel bearing and it still makes this sound.
It doesn't always come from the exact same place. It's always under the driver's side, but sometimes on the side, sometimes under my left foot and sometimes kind of behind my seat. Any ideas? It's driving me crazy and I want to get it fixed while it's still under warranty.
Thanks in advance for any ideas!

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[Grumpy2]

Started about a month ago at Lake Tahoe, perhaps related to the cold? Like a partly empty plastic pop bottle with the cap on under the back seat?

 

[iam7foot1]

Started about a month ago at Lake Tahoe, perhaps related to the cold? Like a partly empty plastic pop bottle with the cap on under the back seat?

Thanks for the reply! I thought that maybe it might be related to the cold as well but it seems like it doesn't matter whether it's cold or not. It's VERY loud and the truck's body is made of aluminum. I'm thinking it's one of the aluminum panels under the truck shifting and wondering if any other Lightning or F150 owners have experienced this.

 

[TaxmanHog]

Thanks for the reply! I thought that maybe it might be related to the cold as well but it seems like it doesn't matter whether it's cold or not. It's VERY loud and the truck's body is made of aluminum. I'm thinking it's one of the aluminum panels under the truck shifting and wondering if any other Lightning or F150 owners have experienced this.

we've had extremely rare reports of missed welding of panels, I hope that's not your situation.

 

[iam7foot1]

we've had extremely rare reports of missed welding of panels, I hope that's not your situation.

Thank you for letting me know about this possibility. Do you know how I would go about finding if this might be happening for me?

 

[TaxmanHog]

Thank you for letting me know about this possibility. Do you know how I would go about finding if this might be happening for me?

I don't, the incident I recall was related the forward part of cab where panel was not welded correctly and waterproofing failed leading to water in the cab.

I'd take a close look at rock shields under the truck, look for debris caught between them and the cab floor, motor units or battery pack.

If you've taken it off road and scrapped the guards look for damage to it that could be causing this sound.

 

[Mach Turtle]

Particular sized branches in a wheel well?

From my experience with an XLT SR, there's no substitute for getting on the ground and having a look underneath the cab and/or bed (in park, e-brake on, power off, wheels chocked, vehicle chained to the ground as a captured beast...I live on a steep hill). Then wiggle various metal and plastic panels, not real hard, just enough to see what's loose.

Of course, a careful look around the cab first with gentle prodding of plastic parts wouldn't be a bad idea either, and it's easier. My XLT came with a substantial piece of plastic wrapper stuck between the bed and cab which didn't make much noise but would have if it were slightly thicker.

Here's hoping your noise is coming from a random bit of something and not a defect in welding or fastening...or you can just tighten a screw or two and fix the problem...or the chipmunks that have taken up residence decide to move elsewhere and don't develop a taste for orange wires.

 

[waasiw]

Hi all! '23 XLT Lightning SR owner for about a year now. About a month ago, I started hearing an intermittent sound once every 20-30 minutes coming from under the driver's side. The best I can describe the noise is like a loud aluminum soda can crunching. It sounds like aluminum is popping in and out of place. I took it to the dealer and they thought it might be the wheel bearing. They replaced the wheel bearing and it still makes this sound.
It doesn't always come from the exact same place. It's always under the driver's side, but sometimes on the side, sometimes under my left foot and sometimes kind of behind my seat. Any ideas? It's driving me crazy and I want to get it fixed while it's still under warranty.
Thanks in advance for any ideas!

There is a recall for some trucks which did not have a suspension bolt torqued properly in the left front. If the suspension comes apart, the vehicle will pull to the left and stop suddenly. you can look up your vin. My truck has this recall and the dealer does not yet have a fix for it, but I'd head straight to the dealer, (do not pass go, do not collect $200 in Monopoly speak) in case yours is coming loose!


https://www.ford.com/support/how-tos/recall/recalls-and-faqs/is-there-a-recall-on-my-vehicle/

 

[iam7foot1]

There is a recall for some trucks which did not have a suspension bolt torqued properly in the left front. If the suspension comes apart, the vehicle will pull to the left and stop suddenly. you can look up your vin. My truck has this recall and the dealer does not yet have a fix for it, but I'd head straight to the dealer, (do not pass go, do not collect $200 in Monopoly speak) in case yours is coming loose!


https://www.ford.com/support/how-tos/recall/recalls-and-faqs/is-there-a-recall-on-my-vehicle/

Thanks for your reply! I'm not seeing this recall anywhere with a Google search for any Ford trucks. Can you please provide a link for this?

 

[Maineiac12]

Thanks for your reply! I'm not seeing this recall anywhere with a Google search for any Ford trucks. Can you please provide a link for this?

It is stickied at the top of the forum…

https://www.f150lightningforum.com/...-impacting-certain-2023-to-2024-builds.23506/

 

[waasiw]

Thanks for your reply! I'm not seeing this recall anywhere with a Google search for any Ford trucks. Can you please provide a link for this?

https://www.f150lightningforum.com/...-impacting-certain-2023-to-2024-builds.23506/

here it is on the forum with Ford links

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