I see that this problem of clunking I quite wide spread. I too had this problem. I originally got the recall done because my front left coil was busted in 2 places. They had to order the coils and would not let me take my car sighting a Saftey Hazard!
Oh well the gave me a loaner (damn 4cyl).
But I returned just this Friday complaining of the clunk. The mechanic got in there and looked at the guards (they actually let me into the service bay to watch) and couldn't find a problem. So we went for a test drive, he heard the clunk and back to the service bay we go.
The mechanic then took off the guards and examined them, there where signs of rubbing(catching more like it) on the top edge of the inside guard and on the bottom edge of the outside guard. After confering with the service manager they removed the guards and he contacted some higher up Ford service guy.
GUESS WHAT?
There is an "UPDATED" Spring Guard Kit. It's on order and I hope it doesn't do it when the put the new ones back in.
At least we aren't paying for it! Imagine the bill I would have had if I had replaced the coils before the recall.
