For those with clunks/noises/knocks. 3 easy fixes.
I've been frustrated for a while with three different clunks, knocks, and noises. I finally got them figured out and hope that this post will help a few people.
Clunk 1: This one was fixed the first time I went in. Dealer found it quickly. Going over speed bumps, noticeable clunk in front suspension: Dealer re-tightened loose strut mounts, clunk went away.
These 2 took a few trips to the dealer to figure out and will be explained together in detail from a post I made in another thread:
Clunk 2: Steering colum looseness/vibration/feedback/clunk
Clunk 3: Going from R to D, loud metallic clunk
YESSSS!!! Finally got it figured out! Had NOTHING to do with the trans like I dreaded! I talked with a Ford Tech and he rode in the car with me. We went from D-R-D-R over and over and found out it wasn't the trans making the knocking noise, it was the brake pad shims. Sounds crazy that they could make that loud of a noise, but that's what it was. Every time he hit the brakes, it would knock, and I was thinking it was the trans shifting. Turns out that the shims weren't designed to clamp on tightly and so they move a little when the piston presses on them and there's 2 or 3 so when they slap together they make a loud noise. The grease had worn off of them (Ford puts a few drops on them instead of coating them) and so there was no buffer between them. All we had to do was put some caliper grease on them and the sound completely went away.
The knocking and feedback in the steering wheel was due to a Mazda 6 TSB for lack of lube on the telescoping steering colum splines and coupler. He sprayed some white lithium grease on them and the problem completely went away. Two friggin' easy fixes and I LOVE my car again and don't feel like setting it on fire and rolling it down a hill, lol. Man, I got all worked up over almost nothing...it's always something small like that that's easily fixed but seems like the end of the world, haha. Now my car is perfect again!
The cool thing is that the Tech let me stay in the shop with him while he worked on my car and showed me everything he was doing. Props to him for fixing something easy that the other two trips to the shop couldn't.