'97 AWD transfer case makes a banging noise.

thebings · 10-22-2010, 04:08 PM

I have a '97 AWD explorer that has developed a loud banging noise coming from the front drive shaft or the transfer case. I removed the front shaft and the noise stopped (car is on lifts) however the shaft seems to be ok. The rubber boot is good and when I flex/rotate the joint, I don't feel any binding. Should I go ahead and replace the shaft or do you think the noise was coming from the transfer case. Like others have pointed out, the t-case is still turning even without the shaft attached, but it does not have any load on it. Appreciate any advise and help. Thanks
Don

swetrid · 10-22-2010, 04:25 PM

front driveshaft definitely

thebings · 10-23-2010, 09:31 AM

A web site that sells the drive shaft says it is important to check the transfer case before installing a new shaft because a bad transfer case will destroy the new shaft. How would I check the transfer case?
Don

*Joey P* · 10-23-2010, 09:39 AM

does it happen only on acceleration? I had the same problem that happened only under acceleration and when I removed the shaft, it looked good, I replaced it and it ultimately ended up being the transfer case. I replaced the transfer case with a used one and I was good to go. I suspected the chain inside the AWD case was stretched out or something. How many miles on your vehicle?

thebings · 10-23-2010, 01:42 PM

Thanks for the reply Lil Bo Peep. No mine makes the banging during steady speed, slowing down, or accelerating. It will be really bad and then stop for a mile or two then start again. Turning into a drive way seems to make it worse. I have found a company that makes a repair kit for the CV, Rock Auto sells it for $102. I think I will install this kit and see what happens. Here is a link to the kit.
http://www.rockauto.com/catalog/moreinfo.php?pk=2425736
Don

**BrooklynBay** · 10-23-2010, 09:40 PM

Welcome to this forum! I've moved your thread into the transmissions & transfer cases section.

*Joey P* · 10-24-2010, 09:07 AM

Hmm. Yours is a 5.0 or a 4.0? Rebuilding the front drive shaft won't hurt either way. I'd check out the rear drive shaft too. Can you "feel" the banging sound under your feet when it happens? Around the location of the transfer case area? That kit you posted should be fine. Mine was a '96 5.0 and it had a different front drive shaft. It was a double cardan joint and not a cv on the front drive shaft.

thebings · 10-24-2010, 09:26 AM

It is the 5.0 liter. The AWD with the CV joint was the only option with the V-8 in '97. With the vehicle on blocks and underneath, it sounded like and felt like it was coming from the front drive shaft. Using a stethscope, it was not over pronounced at the transfer case or the front differential. Yes I plan to change the universal joints on the front and rear axle. Thanks for your reply.

ponch68 · 10-25-2010, 12:13 PM

Hope its the driveshaft, but I had the same issues with banging while accelerating, regardless of speed. My turned out to be the transfer case.

thebings · 10-25-2010, 04:27 PM

I took the CV joint apart today and found a cracked inner race and one ball with rough nicks. Still waiting for my CV repair kit, I will post again when I get it installed but will be next week sometime. Thanks for all your input.
Don

thebings · 11-02-2010, 09:53 PM

Installed new CV joint today and happy to say it fixed the problem. The CV kit was good quality and easy to install.

fast99f350 · 11-02-2010, 10:03 PM

i have a question. What is the brown wire mod for the control tract?

**BrooklynBay** · 11-02-2010, 11:57 PM

Thanks for the update! Did you replace all of the CV joints or just the one that was damaged?

thebings · 11-03-2010, 07:56 AM

This was the CV joint on the aft end of the front drive shaft. The fwd end has a universal joint which I replaced. So I only replaced the one CV joint.

Explorer Junky · 11-18-2010, 04:38 PM

Quote:

Originally Posted by thebings

Thanks for the reply Lil Bo Peep. No mine makes the banging during steady speed, slowing down, or accelerating. It will be really bad and then stop for a mile or two then start again. Turning into a drive way seems to make it worse. I have found a company that makes a repair kit for the CV, Rock Auto sells it for $102. I think I will install this kit and see what happens. Here is a link to the kit.
http://www.rockauto.com/catalog/moreinfo.php?pk=2425736
Don

I tried to get to this link and all it does is show me a picture. Can you send me a better link that will let me see price and maybe order. Mine clunks when shifting into gear and maybe the clunking noise I hear when driving down bumpy gravel and dirt roads? Either way, its got 200,000 on it! My wheel hubs are original, could that be it also????

thebings · 11-18-2010, 10:47 PM

Here is the url to the mfg page.
http://www.dormanproducts.com/p-34479-932-201.aspx
Don

thebings · 11-18-2010, 10:50 PM

Tried to post a link to Rockauto where I bought mine but having trouble. Just go to rockauto.com and search for MFG name Dorman and part number 932201
Don

Explorer Junky · 11-19-2010, 11:40 AM

Thanks fellas! I just might have to order it this weekend. I got under there and grabbed the shaft by hand and gave it a good strong twist and it clanks, and clanks when shifting into gear. Also, had my reluctant wife ride with me and ask if she heard it on her side or mine and she said drivers. So, hope this is it. Then if that doesn't do it, then its the hub next!

Thomsoningreen · 11-30-2010, 08:11 PM

I have the said kit above but not sure how it goes together. Are the parts pressed together to assemble?

thebings · 11-30-2010, 10:13 PM

The domed end cover is a snug fit but not a pressed fit, it's just the gasket that holds it tight. I don't remember for sure but I think I held the bearing assemby by hand then tapped the end of the shaft (the end with the universal joint) on a piece of wood which broke loose this cover. Once the cover is removed, then you can remove the snap ring and pull off the bearing assembly. When I put the unit back into the vehicle, I tightened the bolts a little at a time to pull it back together straight. Hope this helps

10-22-2010, 04:08 PM	#1
thebings Wannabe Elite Explorer Join Date: Oct 2010 Posts: 10 Vehicle Specs (Original Poster)	'97 AWD transfer case makes a banging noise. I have a '97 AWD explorer that has developed a loud banging noise coming from the front drive shaft or the transfer case. I removed the front shaft and the noise stopped (car is on lifts) however the shaft seems to be ok. The rubber boot is good and when I flex/rotate the joint, I don't feel any binding. Should I go ahead and replace the shaft or do you think the noise was coming from the transfer case. Like others have pointed out, the t-case is still turning even without the shaft attached, but it does not have any load on it. Appreciate any advise and help. Thanks Don

10-22-2010, 04:25 PM	#2
swetrid Wannabe Elite Explorer Reading Pa 2001 Eddie Bauer Join Date: Sep 2010 Posts: 1,883 Vehicle Specs	front driveshaft definitely __________________ Resident Ford Tech for the last 17 years, 2001 Eddie Bauer 5.0L, Cherry Bomb Cat back, 2010 Ecoboost Flex

10-23-2010, 09:39 AM	#4
Joey P On my 5th Explorer Lakewood, CO 1999 Ford Explorer EB 5.0 Join Date: Jan 2001 Posts: 1,782 Vehicle Specs	does it happen only on acceleration? I had the same problem that happened only under acceleration and when I removed the shaft, it looked good, I replaced it and it ultimately ended up being the transfer case. I replaced the transfer case with a used one and I was good to go. I suspected the chain inside the AWD case was stretched out or something. How many miles on your vehicle? __________________ There are two types of people in this world: 1.Those who get lemons and make lemonade. 2.Those who get lemons and squirt the juice in their eyes. Updated Mug shot 2/12/09

10-23-2010, 09:40 PM	#6
BrooklynBay Aerostar Forum Moderator Brooklyn, NY 88 89 93 95 96 Aerostars Join Date: Nov 2005 Posts: 45,689 Vehicle Specs	Welcome to this forum! I've moved your thread into the transmissions & transfer cases section. __________________ My list of useful threads. My photo gallery. My product reviews. My list of items for sale. Aerostar owners thread. Aerostar parts work in Explorers, Rangers, and Bronco II thread. History of the Aerostar thread. Aerostar Forum. New Members Forum. Ford/Lincoln/Mercury Forum.

10-24-2010, 09:07 AM	#7
Joey P On my 5th Explorer Lakewood, CO 1999 Ford Explorer EB 5.0 Join Date: Jan 2001 Posts: 1,782 Vehicle Specs	Hmm. Yours is a 5.0 or a 4.0? Rebuilding the front drive shaft won't hurt either way. I'd check out the rear drive shaft too. Can you "feel" the banging sound under your feet when it happens? Around the location of the transfer case area? That kit you posted should be fine. Mine was a '96 5.0 and it had a different front drive shaft. It was a double cardan joint and not a cv on the front drive shaft. __________________ There are two types of people in this world: 1.Those who get lemons and make lemonade. 2.Those who get lemons and squirt the juice in their eyes. Updated Mug shot 2/12/09

10-23-2010, 09:31 AM	#3
thebings Wannabe Elite Explorer Join Date: Oct 2010 Posts: 10 Vehicle Specs (Original Poster)	A web site that sells the drive shaft says it is important to check the transfer case before installing a new shaft because a bad transfer case will destroy the new shaft. How would I check the transfer case? Don

10-23-2010, 01:42 PM	#5
thebings Wannabe Elite Explorer Join Date: Oct 2010 Posts: 10 Vehicle Specs (Original Poster)	Thanks for the reply Lil Bo Peep. No mine makes the banging during steady speed, slowing down, or accelerating. It will be really bad and then stop for a mile or two then start again. Turning into a drive way seems to make it worse. I have found a company that makes a repair kit for the CV, Rock Auto sells it for $102. I think I will install this kit and see what happens. Here is a link to the kit. http://www.rockauto.com/catalog/moreinfo.php?pk=2425736 Don

10-24-2010, 09:26 AM	#8
thebings Wannabe Elite Explorer Join Date: Oct 2010 Posts: 10 Vehicle Specs (Original Poster)	It is the 5.0 liter. The AWD with the CV joint was the only option with the V-8 in '97. With the vehicle on blocks and underneath, it sounded like and felt like it was coming from the front drive shaft. Using a stethscope, it was not over pronounced at the transfer case or the front differential. Yes I plan to change the universal joints on the front and rear axle. Thanks for your reply.

10-25-2010, 12:13 PM	#9
ponch68 Wannabe Elite Explorer San Antonio '97 Explorer XLT Join Date: Feb 2009 Posts: 36 Vehicle Specs	Hope its the driveshaft, but I had the same issues with banging while accelerating, regardless of speed. My turned out to be the transfer case.

10-25-2010, 04:27 PM	#10
thebings Wannabe Elite Explorer Join Date: Oct 2010 Posts: 10 Vehicle Specs (Original Poster)	I took the CV joint apart today and found a cracked inner race and one ball with rough nicks. Still waiting for my CV repair kit, I will post again when I get it installed but will be next week sometime. Thanks for all your input. Don

11-02-2010, 09:53 PM	#11
thebings Wannabe Elite Explorer Join Date: Oct 2010 Posts: 10 Vehicle Specs (Original Poster)	Installed new CV joint today and happy to say it fixed the problem. The CV kit was good quality and easy to install.

11-02-2010, 10:03 PM	#12
fast99f350 Wannabe Elite Explorer New Jersey 97 explorer xlt Join Date: Nov 2010 Posts: 1 Vehicle Specs	i have a question. What is the brown wire mod for the control tract?

11-02-2010, 11:57 PM	#13
BrooklynBay Aerostar Forum Moderator Brooklyn, NY 88 89 93 95 96 Aerostars Join Date: Nov 2005 Posts: 45,689 Vehicle Specs	Thanks for the update! Did you replace all of the CV joints or just the one that was damaged? __________________ My list of useful threads. My photo gallery. My product reviews. My list of items for sale. Aerostar owners thread. Aerostar parts work in Explorers, Rangers, and Bronco II thread. History of the Aerostar thread. Aerostar Forum. New Members Forum. Ford/Lincoln/Mercury Forum.

11-03-2010, 07:56 AM	#14
thebings Wannabe Elite Explorer Join Date: Oct 2010 Posts: 10 Vehicle Specs (Original Poster)	This was the CV joint on the aft end of the front drive shaft. The fwd end has a universal joint which I replaced. So I only replaced the one CV joint.

11-18-2010, 10:47 PM	#16
thebings Wannabe Elite Explorer Join Date: Oct 2010 Posts: 10 Vehicle Specs (Original Poster)	Here is the url to the mfg page. http://www.dormanproducts.com/p-34479-932-201.aspx Don

11-18-2010, 10:50 PM	#17
thebings Wannabe Elite Explorer Join Date: Oct 2010 Posts: 10 Vehicle Specs (Original Poster)	Tried to post a link to Rockauto where I bought mine but having trouble. Just go to rockauto.com and search for MFG name Dorman and part number 932201 Don

11-19-2010, 11:40 AM	#18
Explorer Junky Wannabe Elite Explorer Grand Rapids, Mi 1997 XLT 4 dr 5.0 Join Date: Mar 2010 Posts: 428 Vehicle Specs	Thanks fellas! I just might have to order it this weekend. I got under there and grabbed the shaft by hand and gave it a good strong twist and it clanks, and clanks when shifting into gear. Also, had my reluctant wife ride with me and ask if she heard it on her side or mine and she said drivers. So, hope this is it. Then if that doesn't do it, then its the hub next!

11-30-2010, 08:11 PM	#19
Thomsoningreen Wannabe Elite Explorer Troutman, NC 1997 Explorer XLT 4WD Join Date: Aug 2010 Posts: 4 Vehicle Specs	CV rebuild anyone know how to put this together? I have the said kit above but not sure how it goes together. Are the parts pressed together to assemble?

11-30-2010, 10:13 PM	#20
thebings Wannabe Elite Explorer Join Date: Oct 2010 Posts: 10 Vehicle Specs (Original Poster)	The domed end cover is a snug fit but not a pressed fit, it's just the gasket that holds it tight. I don't remember for sure but I think I held the bearing assemby by hand then tapped the end of the shaft (the end with the universal joint) on a piece of wood which broke loose this cover. Once the cover is removed, then you can remove the snap ring and pull off the bearing assembly. When I put the unit back into the vehicle, I tightened the bolts a little at a time to pull it back together straight. Hope this helps