[etugg]

Has anyone put on a aftermarket drive shaft yet? Are they available? Or would I just have to find a shop to make a custom one?

I'm having trouble with that popping noise on my 2011 6.7 and I'm deleted sooo no trip to the dealer for me. I probably haven't helped the situation at all with all the extra power, but its worth it!

BTW, I've taken the driveshaft off and all the U-joints feel super smooth, so I think it might be something internal. Just an idea tho.

 

[Gatorstroke 6.0]

What about just taking it out and bringing it with you to a driveshaft shop and seeing if they can balance it for you or something? Maybe the weights are just messed up on it.

 

[FordFascist]

Throwing parts at the problem is probably not going to solve it - especially an 8 foot long driveshaft that is 5" in diameter. Those are definitely not cheap.

You may want to figure out what the popping noise is first, so why not describe specifically what conditions it occurs under.

 

[etugg]

It's definitely not a balance problem, and I don't think it's a universal joint either, so I'm guessing it's something structurally. The noise occurs when just putting pressure on it by going from drive to reverse back to drive. (foot on the brake with very little throttle) I can also hear it at speed when going from power to no throttle. (engine braking)

I've read about stock 6.7s having the same problem so I didn't want to back with OEM. I actually talked to the guys at The Driveshaft Shop and they're gonna send me an estimate for what they suggest. Probably going to be around $700...

 

[FordFascist]

It's definitely not a balance problem, and I don't think it's a universal joint either, so I'm guessing it's something structurally. The noise occurs when just putting pressure on it by going from drive to reverse back to drive. (foot on the brake with very little throttle) I can also hear it at speed when going from power to no throttle. (engine braking)

I've read about stock 6.7s having the same problem so I didn't want to back with OEM. I actually talked to the guys at The Driveshaft Shop and they're gonna send me an estimate for what they suggest. Probably going to be around $700...

Again, if you want to throw away $700, mail it to me. You need to do some due diligence and figure out what the issue is, rather than throwing parts at it. A clunk could be from a loose pinion gear caused by a bad bearing, or from issues in the carrier. You could also have loose u-bolts in the rear. There will be some noise from the axle wrapping from changing torque loads which is entirely normal in a truck.

 

[etugg]

Again, if you want to throw away $700, mail it to me. You need to do some due diligence and figure out what the issue is, rather than throwing parts at it. A clunk could be from a loose pinion gear caused by a bad bearing, or from issues in the carrier. You could also have loose u-bolts in the rear. There will be some noise from the axle wrapping from changing torque loads which is entirely normal in a truck.

First off, thanks for your advice!

Hah nice try, but I wouldn't spend the money unless I felt like it would solve the problem. Also, it's more of a sharp "ping" / "pop" metal noise. (definitely not a clunk) And I was born at night but not last night, so I can tell that this is not a normal noise caused by axle wrap. I mean, it happens at idle to 10% throttle.

I just got under the truck and placed my hand on the shaft while a friend caused it to happen (changing from D to R) and a ping can be felt. Definitely makes me still think it's internal/structural to the shaft itself. I've done some reading, on this and other forums, and found other guys describing the same problem. The dealer replaced the driveshaft and solved the problem. One hasn't heard it again, but the other had the problem come back after a few thousand miles; the main reason I don't want to go back stock if I do replace it.

I plan to take it off again sometime this week and feel the Universal joints another time. I know they all felt smooth and consistent the last time and the noise was just the same, and then go from there.