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Here is mine. Only difference on mine is they actually replaced the cowl grill screen part number LJ6Z18D395B.

Mine was fixed by replacing a deflector under the cowl. Was installed wrong from the factory. Water was coming in through thr AC fresh air intake and soaking through the cabin filter. See below thread. https://www.mavericktruckclub.com/forum/threads/water-leak.31072/

Good read on the system operation at a high level for those who are not familiar with it. https://driving.ca/features/feature-story/deep-dive-2022-ford-mavericks-awd-system-explained

Pictures of the csv files for clunk and no clunk events. The first tab is the clunk event and the second tab is the no clunk event titled forscan testing.

I feel like I need to add some additional information to the pictures above. As mentioned previously I think the main PID of interest here is RDU_MTR_POS. It is the PID that changed drastically after the AWD module adaptive learn reset. The pink and yellow lines also appeared to be different...

I am leaning towards the RDU, reasoning detailed below: - The clunk noise is very noticeable from the rear of the vehicle. No perceptible noise from the front. - There are multiple service bulletins out on other Ford vehicles with the same style AWD system with a rear disconnect drive unit...

In my experience the fluid change did nothing. However, I am glad I changed the factory fluid out. The drain plug magnet had a lot of magnetic fuzz on it. No shavings large enough to feel in your hand. Just break in material more than likely. I had also heard rumors of under-filled PTUs and...

Issue is not related to anything in the vehicle or in the bed. I removed everything from the truck initially to rule that out. I usually keep quite a few emergency items under the rear seat and was thinking along the same lines as you.

Since you are going the warranty route I would just stay on the dealer and try to get a resolution. You can also work with the ford account on this forum to get a case number opened up. I doubt getting a case number opened helps very much. In my experience in the past it does absolutely nothing...

It is interesting that the TCU relearn fixed yours. I don't think the TCU has any direct control over the RDU. Only the AWD module should. Now those two modules certainly communicate and I am sure there are programmed dependencies between them during operation. I only performed the AWD module...

I think the main parameter of interest out of those that I posted is RDU_MTR_POS. I believe the magnitude of that value corresponds to the clutch engagement in the RDU. I highly recommend forscan, lots of tutorials out there. It is a great diagnostic tool for nuanced issues like this one.

Truck drove perfectly today to and from work in lots of stop and go traffic where it would consistently clunk slowing down.

I should mention as well that I had about 5 recordings of clunk events that all looked identical to the first picture so I didnt post multiple pictures. However, I did post multiple pictures of the no clunk events because they all looked slightly different.

I checked under the truck and everything is secure, no suspension movement anywhere, driveshaft and half shafts felt solid at the RDU. So I went and hooked up forscan and got it to clunk immediately. It happens right at 16mph only while decelerating. See attached forscan images of PTU and RDU...

Good point on having everything secure. Will double check everything before forscan diagnostics. However, I would think if it was something loose it would make the noise during other driving conditions especially over bumps.

I've noticed for the last few thousand miles that randomly during deceleration around 10-16 MPH I get a clunk coming from the rear of the truck during deceleration. It doesn't occur during a downshift. It's between downshifts and feels like a bowling ball is rolling around in the bed. Wondering...

How much fluid did your RDU take? Mine was right at 0.5qt with the vehicle level. That seems to match up with the OPs youtube video but does not match the discussed fill amount others have mentioned.

So I've noticed an odd phenomenon from my 23 ecoboost lately. Anywhere between 60-80 mph I can hear a very distinct ring or whine noise coming from the speakers in my truck only when ever so slightly pressing the gas. It goes away as soon as I let off the gas or apply any appreciable amount of...

Removed the alignment pins over the weekend exactly as described here and am happy to report the cold weather rattle noise on both sides is now completely gone!

I did the software update last week with no issues. Initially seemed to fix the jittery backup camera and random audio popping noise. Both started back again this morning pulling out of the driveway. Android auto connectivity seems to be improved still.