Was here with the van, runs well, now the girlfriends 2003 F250 superduty 4wd has a really loud clunk in the front end when she hits bumps. I think its the front axle shaft banging on the housing. I shoved some sponge material around the shaft which seems to have lessened the noise and the feel. I think I remember reading somewhere about a seal of sorts that's suppose to go between the axle and the housing----her truck has no seal right close to the universal joint that I can see. I can move the universal joint up, down, back & forth by hand, and cause it to hit the axle housing.
Is there a Ford part available I can put between the shaft and the housing???

 

If I understand what you are telling us, that U-joint should not be that movable and you might want to check out the wheel bearing on that side.

 

I just watched a UTube demonstration on changing that seal. Your right. If one would choose to get that far into the deal, everything should get changed. May as change the inner differential seals while its all apart. Looks like a once in a 10 year job to me. I think this is going to take some time.

 

There is an inner seal that requires a special tool to install. You might want to check with a Ford parts dept to make sure you get the right one and confirm if you will require that tool to do the job.