Hi guess this has been posted a million times already but thought i'd share my problem since ford can't fix it.

have a bf xr6 ute that's been lowered 2 inches, now the problem i have since i've had it 5 months is a weird binding clunking noise from the rear diff, been to ford mechanics about 5 times to fix but have started to give up hope on them, we have adjusted handbrakes countless times, even replaced rotors incase rh side was warped on the inside of the hub were the h/brake shoe grab, got new brake pads. been assured the diff is ok internally, changed to thicker grade 90 ?/140 with lsd additive. been assured again that the wheel bearings are ok. they have had the ute on the hoist countless times greased everything, checked everything was tight etc.
Various stages they have had the ute and could not hear a single thing but every morning i drive it from work i hear it. One week i drop it off to them and said have it for the whole week- drive it around, take it home just use it as normal, not just drive around the block & workshop alley as they do in there 'road test'. They did this but i still think they didn't as there was bugger all k's done.
Fords lastest answer or fix from the service manager is to drive around and don't use the handbrake and get this drive down a quite road and do about 5 spin outs on each rear wheel just incase the diff cones have ' glossed up ' ( excuse the terms i think that's what he said ).
my lastest thoughts is they won't anything to do with this, spend there time or labour on it. suspect they have not done a through check especially the wheel bearings even though i'm told they are ok.

all this drama started when i took it to them for a handbrake adjustment and diff pinion seal replacement and new brake pads......

any thoughts....

Do the utes have CV shafts like on the sedans ? If it does maybe one is a bit worn or loose.

No they don't i'm sure as they have a solid axle unlike the sedans with rear IRS which is like a cv joint for each axle, I know the sedans are known for the diff bushes problems but utes with solid axles ?

like i said there is not much too the axle set up, been told by ford that the ba - bf are known for handbrake issues because the shoes are not self centering and can take a while to get back into normal position in the hub - this is what i thought was happening with mine hence all the visits and replacement rotors but the noise is still there - hence fords advice is to drive around and not use the handbrake!!

they don't see it a big enough issue to tear down the diff or pull out the axles to check the bearings or bent axles in case they find nothing wrong and have to look elsewhere.

do they have a carrier / hanger bearing for the drive shaft ? - i don't know as i can't remember without getting underneath the ute. think the sedans have one because it's a double jointed shaft..?

so far all the work & time ford have been doing has been free but making no progress to fix the noise if i start taking it somewhere else it will cost me big time, i'd rather stick with ford and hopefully find the problem and at last say to them this is the problem fix it.

I have warranty but they are reluctant to go ahead with anything in case they get the bill for a tear down from there diff specialists only to be told there is nothing wrong.

i'll add the nosie is really noticeable in the cabin at very slow speeds accelerating or deccelerating on smooth roads

sticky situation ...