2025 AWD Hybrid making thunk or thud noise from the rear at around 13 mph when braking

[ListedGuru]

Just purchased my dads 23 ecoboost awd from him on Monday, has 29k miles all from him he got new. While driving home i heard and felt it do something funny at low speed right around 13mph. Took to my Ford dealership yesterday and sure enough it needs a new rear differential. It has the 4k towing package as well.

Do you happen to know if your dad every heard and or felt the 13mph thunk or clunk that your describing? Any chance you heard it previously if you drove his truck or rode with him? Also I'm curious how they can up with the diagnosis that it needs a new rear differential? I do know of at least one other person who had the thunk and their dealer replaced the rear diff and the new rear diff started making noise after a few thousand miles IIRC.

Please keep us up to date as to how the repair goes and if replacing the rear diff fixes the thunk or if it comes back at some point. My truck makes the noise all the time when it's typically around 40 degrees or warmer but I'm waiting to take it in until someone hopefully figures out what is causing the noise and what the fix actually is.

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[gracmr]

He swears he never heard or felt it since he owned it. I live in Ocala and picked it up from him in Jacksonville. Got on the highway rt away everything normal but once i got to the backroads i called my wife and said something isnt right, i at first couldnt tell if it was from front or rear but definitely heard it and felt a jolt especially when turning left really slow. Got the tag put on Monday and drove it to my shop, had my fleet manager take it for a spin and he said oh yeah their is something up. Brought to our local dealer who we have good relationship with and made them drive with him in truck, he noticed rt away too. 2 hours later Ford called said it needs a new rear differential give them a week or so to get it in. Ill report back once i get it back from them but honestly ill have my fleet mechanic take for a bit as i was going to give this to my son but am now not sure what im going to do with it. My dad said he brought to dealer for all his services and fluids but he isnt sure if that was ever done or not. Ill have to see if he can find his paperwork or not

 

[retiredmike]

Can you ask your dad if he ever had the RDU fluid changed?

I noticed mine doing it around 12,000 miles (a guess). My RDU oil isn't old.

 

[retiredmike]

Do you happen to know if your dad every heard and or felt the 13mph thunk or clunk that your describing? Any chance you heard it previously if you drove his truck or rode with him? Also I'm curious how they can up with the diagnosis that it needs a new rear differential? I do know of at least one other person who had the thunk and their dealer replaced the rear diff and the new rear diff started making noise after a few thousand miles IIRC.

Please keep us up to date as to how the repair goes and if replacing the rear diff fixes the thunk or if it comes back at some point. My truck makes the noise all the time when it's typically around 40 degrees or warmer but I'm waiting to take it in until someone hopefully figures out what is causing the noise and what the fix actually is.

Same with mine. Colder temps, no thud.

 

[gracmr]

Got a call from Ford yesterday evening truck was ready. Thought it was odd it was done so fast. Had my mechanic pick up this morning and they let him know they dont have an rdu to swap but just rebuild. Little disappointing but we will see what happens. Posted this receipt if anyone needs the tsb numbers. Hes going to drive for a bit and then will report back

 

[ListedGuru]

He swears he never heard or felt it since he owned it. I live in Ocala and picked it up from him in Jacksonville. Got on the highway rt away everything normal but once i got to the backroads i called my wife and said something isnt right, i at first couldnt tell if it was from front or rear but definitely heard it and felt a jolt especially when turning left really slow. Got the tag put on Monday and drove it to my shop, had my fleet manager take it for a spin and he said oh yeah their is something up. Brought to our local dealer who we have good relationship with and made them drive with him in truck, he noticed rt away too. 2 hours later Ford called said it needs a new rear differential give them a week or so to get it in. Ill report back once i get it back from them but honestly ill have my fleet mechanic take for a bit as i was going to give this to my son but am now not sure what im going to do with it. My dad said he brought to dealer for all his services and fluids but he isnt sure if that was ever done or not. Ill have to see if he can find his paperwork or not

Got a call from Ford yesterday evening truck was ready. Thought it was odd it was done so fast. Had my mechanic pick up this morning and they let him know they dont have an rdu to swap but just rebuild. Little disappointing but we will see what happens. Posted this receipt if anyone needs the tsb numbers. Hes going to drive for a bit and then will report back

Thanks for posting this. I'm wondering if this is something different than the 13 MPH thunk, clunk or thud we are talking about here? Per the workorder it sounds like the noise was described as a grinding noise. When you heard the noise was it a constant noise or did it come and go? The noise I'm talking abut the (clunk, thunk, thud) happens when slowing down and you cross that 13 MPH mark and you are greeted with a pretty loud thunk but it's quick and goes away immediately until the next time you slow down and hit the 13 mph mark again. I'm just curious as your issue seems to be different.

Whatever the case may be hopefully they got it fixed for you and the problem doesn't come back at some point.

 

[Mox4615]

Got a call from Ford yesterday evening truck was ready. Thought it was odd it was done so fast. Had my mechanic pick up this morning and they let him know they dont have an rdu to swap but just rebuild. Little disappointing but we will see what happens. Posted this receipt if anyone needs the tsb numbers. Hes going to drive for a bit and then will report back

Might just be the wording but this doesn’t sound like this is pertaining to the same issue that the thread is about as the noise isn’t a grinding noise at all, far from it actually.

 

[bobojay49]

I just found this thread. I've got a '25 hybrid AWD that's doing this exact thing, thud, clunk at 13mph while slowing down. Mine started at about the 5k mile mark, and it's getting worse, harder, louder, now with 6900 miles.
I'm a car guy and very easily notice these strange sounds and vibrations even without my hearing aids in.
I guess my next step is holler at my dealer. So far this is my second "major" issue with this vehicle. First one was losing the electric power steering twice during the first 3k miles. Fixed itself with an ignition cycle both times. I can see where that would freak someone out that didn't know what was happening.
Our first Ford product is so far not impressing us....

 

[Finnster]

First one was losing the electric power steering twice during the first 3k miles. Fixed itself with an ignition cycle both times. I can see where that would freak someone out that didn't know what was happening.
Our first Ford product is so far not impressing us....

Interesting!
If you can, please start a new thread explaining what happened during the electric power steering loss, if the problem was repaired at a dealership, and let us know how easy or hard it was to steer the maverick without the power steering. Thanks!

 

[ListedGuru]

I just found this thread. I've got a '25 hybrid AWD that's doing this exact thing, thud, clunk at 13mph while slowing down. Mine started at about the 5k mile mark, and it's getting worse, harder, louder, now with 6900 miles.
I'm a car guy and very easily notice these strange sounds and vibrations even without my hearing aids in.
I guess my next step is holler at my dealer. So far this is my second "major" issue with this vehicle. First one was losing the electric power steering twice during the first 3k miles. Fixed itself with an ignition cycle both times. I can see where that would freak someone out that didn't know what was happening.
Our first Ford product is so far not impressing us....

Sorry to hear your now a member of the 13mph thud, thunk and clunk club - also luckily I haven't experienced losing the electric power steering and hopefully don't have to but would be interested in hearing more about the ignition cycle you did to fix it.

Please let us know what your dealer says if you happen to take it in for the 13mph thud, thunk or clunk noise. I too have a 25 AWD Hybrid which I bought brand new in May of 2025 and my truck did not make this noise when I first got it. It just happened one day out of the blue and like you it seems to be getting worse - I have 8900 miles or so on the truck. I haven't taken my truck into the dealer yet as I'm hoping that someone figures out what's causing this issue.

Several of us have also noticed that the thunk noise goes away when it's cold. I'm in Michigan and my truck normally won't make the noise if it's under 40 degrees outside give or take a few degrees. Also if you turn off the traction control you should notice that the noise goes away as maybe the AWD doesn't engage with the TC off?

Here are a few other threads on the subject that have some more discussion if you interested and I've also seen it mentioned a lot of various Maverick facebook groups and on Reddit.

https://www.mavericktruckclub.com/f...the-rear-at-around-13-mph-when-braking.72905/

https://www.mavericktruckclub.com/f...down-braking-at-around-the-13-mph-mark.72957/

https://www.mavericktruckclub.com/f...ms-to-have-disappeared-on-awd-maverick.76483/

 

[icecoast]

Is it possible that its some sort of static discharge from the regen braking? it sounds very similar (albeit much quieter) than other static discharge noises have heard.

 

[JonnyC]

Is it possible that its some sort of static discharge from the regen braking? it sounds very similar (albeit much quieter) than other static discharge noises have heard.

No this affects both hybrid and ecoboost AWD models

 

[retiredmike]

Same with mine. Colder temps, no thud.

Also, no thud when traction control is turned off.

 

[Manollo3]

I took my 25'Hybrid AWD with 4k tow package in for the 10k service a couple of weeks. Made a list of items to be checked and one of them was the thud noise. When I picked up the vehicle the service advisor told me that this is the way it was designed. Will probably take it to another dealer next time and have it checked again. Otherwise, I guess we just have to live with it.

 

[Mox4615]

I’ve quit paying attention to it. I’m almost positive it’s just the AWD components re-engaging after it’s dropping into lower gear since it’s basically a front wheel drive truck at cruising speeds. Just seems that roughly 1 out of 4 happen to get the ones that are noisy about it

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