Been there ...done that.It will return after a month or 2.Something in the fabrication is causing excessive play....this is just a quick fix that doesn't last.VERY frustrating as they should have a recall and replace them with something proper!!I will try the grease fix and report back.
Cheers

 

Exactly. X2

 

Had mine replaced 2 months ago. It's back.

 

You should try this: remove the lower intermediate shaft then put it back without replacing it with a new part. Tight the bolts and see what happens

 

ok, this is my first post, so dont raise hell if i get it wrong. but i have the same noise. i had someone turn the steering wheel back and forth while i check for the noise. i found my noise to go away when i grabbed the steering shaft slip joint boot. thier is a little play in the slip joint causing my noise.

 

The dealer replaced the intermediate shaft in less than an hour under warranty with no questions asked. It resolved my clunking noise. This was about two months ago, so time will tell if the fix endures.

 

I have the clunk but only in the summer when it's 90+ outside. I plan on injecting 5th wheel grease in the shaft boot and see what happens.

 

My conclusion is that it's heat related.

The cold weather along with 5th wheel grease and it's gone.

I noticed the same thing last winter. But once spring/summer arrived it was back.

 

I only get it off road.
I call feel it happening.

Also on hotter days its worse.

 

Tagged for reference.