Vibration/chatter from 60 mph up

calthaus · 04-22-2012, 12:25 AM

I have been searching the forum here and have found several threads similar to this yet many do not continue to post when they find a solution. Maybe they don't...

?

Two years ago I purchased a 02 XLS Auto 4x4 with 145,000 miles from a used car dealership to use for hunting and hauling the dog around. Everyting seemed fine until a few weeks later when I took it down the interstate. It had a terrible noise/vibration/shake (actually kind of bounced and wandered)that started at about 65 mph and did not go away at higher speeds. I assumed it was because of the uneven tires they had on it and just stayed off the interstate and below 65mph until I got some different tires.

Fast forward to now and 5,000 miles later...I just replaced all 4 tires which has dramatically smoothed the ride, however the vibration/noise is still there. The noise is best described as a deep chatter that I can now here actually becomes noticable at about 60 mph, increases to the loudest at 65 and stays that loud up to 80 (have not pushed it beyond as I am afraid something is failing). The rear end does have the whine everyone is so familiar with. This is a much different noise.

After reading others posts, I have tried several things to attempt to narrow down what might be causing it.

Bring it up to 75mph, turn overdrive off, noise stays the same.

Brown Wire Mod to disable power from being applied to front wheels. - no change, noise is the same.

Wheel Bearing check (6 and 12 position) no play. However part of me thinks that driving on those uneven tires for 5,000 miles may have ruined a bearing or two...

Jacked all four wheels off the ground, put it in drive and ran up the speed. There was all sorts of noise from what sounded to be the transfer case and some from the rear end. It was difficult to compare the sound to what is heard on the road as it was much noiser. Almost sounded like the transfer case would not fully engage properly at times. It made clicking noises even at idle speed.

All boot covers are in good shape, Rear drive shaft moves about 1/16 to 1/8" up when I press up where the two shafts connect in the center. Could not find anywhere if that is normal or not. There seems to be a lot of play in driveshafts/tranfercase and differentials.

My next thing to try is to remove the front driveshaft and see if anything changes...

Anyone have any experience with something similar? I really don't want to just start randomly replacing parts.

tlutz211 · 04-22-2012, 12:41 AM

Cv joint on front drive shaft where it connects to transfer case... Even if visually it looks sound, internally it could be fried... This fixed most of my problem with the same exact symptoms (cv joint $125 autozone special order) still have some growling though and and hoping that it will be resolved this weekend with new bushings for upper control arms and camber bolts (mine look fine but do have some play) also if you have done a torsion twist try backing down just a little.

*Wills05xlt4x4* · 04-22-2012, 02:29 AM

Quote:

Originally Posted by tlutz211

Cv joint on front drive shaft where it connects to transfer case... Even if visually it looks sound, internally it could be fried... This fixed most of my problem with the same exact symptoms (cv joint $125 autozone special order) still have some growling though and and hoping that it will be resolved this weekend with new bushings for upper control arms and camber bolts (mine look fine but do have some play) also if you have done a torsion twist try backing down just a little.

Agreed they can be trash and appear ok...
btw No torsion bars on third gens... Struts all around...ifs/irs

tlutz211 · 04-22-2012, 04:27 AM

Ahh... Didn't pay attention to that... I have a bad habit of seeing someone with similar symptoms that I have had and just assuming they are running a comparable year model lol

calthaus · 04-22-2012, 01:58 PM

Thanks for the quick responses. I pulled the front driveshaft, noise is still there at 60 on up. Put the rearend up on jackstands and ran it up to 30 then 60. Crawled under to listen closer and the noise is definetly coming from the differential/half shafts. Sounds like more noise is coming from the drivers side. After shutting down I checked the movement of the half shafts. The drivers side moves in and out much more than the passenger side. How much movement is normal?

calthaus · 04-29-2012, 12:36 PM

OK, I pulled the drivers side rear knuckle and hub. How can I tell if the wheel bearing is bad? When I turn it, it does not "free wheel" and there is a faint noise like there is sand in the bearing. Should it spin pretty easily and keep spinning on its own for a bit?

*buckwill* · 04-29-2012, 01:48 PM

if you have pulled the half shaft and turn the wheel and u can hear or feel anything the bearing is bad and needs changed,,should hear and feel nothing when bearings are good,, buck

calthaus · 04-29-2012, 09:50 PM

I guess I am then getting a new bearing. I also managed to tear the ball joint boot worse than it already was whiltrying too remove the ball joint from the knuckle. Where the heck can I find a new boot? I have searched all over and no luck...

*buckwill* · 04-29-2012, 10:17 PM

andys auto sports 1-800-419-1152,,, ball joint boots for ford explorer,, in COLOR if u want!!!!buck

calthaus · 04-30-2012, 10:18 PM

Thanks. I found a universal boot I can use for now till I order one up. I took the hub to my mechanic who said the bearing seems fine. Said to bring it up and they would put it on the lift and try to find the source. So I put it back together (which was much easier than taking it apart) and took it for a ride. Keep in mind I also changed the gear oil in the differential yesterday. It was dirty and a bit thinner than the new 70w-145 I added. Anyhow, I noticed a change in the symptoms... the noise now starts at 70 MPH vs 60-65. I also noticed that now when I run it up to 80 and get the roaring vibration, if I let off the gas the sound fades for a moment as it starts to slow than comes back. It also seems like after I let off the gas and let the sound fade then accelerate softly just before the sound comes back it also keeps it at bay for a moment.... slack in the rearend? Gears, bearings?

04-22-2012, 12:25 AM	#1
calthaus Wannabe Elite Explorer Minnesota 2002 XLS 4x4 4.0 Join Date: Apr 2012 Posts: 5 Vehicle Specs (Original Poster)	Vibration/chatter from 60 mph up I have been searching the forum here and have found several threads similar to this yet many do not continue to post when they find a solution. Maybe they don't...? Two years ago I purchased a 02 XLS Auto 4x4 with 145,000 miles from a used car dealership to use for hunting and hauling the dog around. Everyting seemed fine until a few weeks later when I took it down the interstate. It had a terrible noise/vibration/shake (actually kind of bounced and wandered)that started at about 65 mph and did not go away at higher speeds. I assumed it was because of the uneven tires they had on it and just stayed off the interstate and below 65mph until I got some different tires. Fast forward to now and 5,000 miles later...I just replaced all 4 tires which has dramatically smoothed the ride, however the vibration/noise is still there. The noise is best described as a deep chatter that I can now here actually becomes noticable at about 60 mph, increases to the loudest at 65 and stays that loud up to 80 (have not pushed it beyond as I am afraid something is failing). The rear end does have the whine everyone is so familiar with. This is a much different noise. After reading others posts, I have tried several things to attempt to narrow down what might be causing it. Bring it up to 75mph, turn overdrive off, noise stays the same. Brown Wire Mod to disable power from being applied to front wheels. - no change, noise is the same. Wheel Bearing check (6 and 12 position) no play. However part of me thinks that driving on those uneven tires for 5,000 miles may have ruined a bearing or two... Jacked all four wheels off the ground, put it in drive and ran up the speed. There was all sorts of noise from what sounded to be the transfer case and some from the rear end. It was difficult to compare the sound to what is heard on the road as it was much noiser. Almost sounded like the transfer case would not fully engage properly at times. It made clicking noises even at idle speed. All boot covers are in good shape, Rear drive shaft moves about 1/16 to 1/8" up when I press up where the two shafts connect in the center. Could not find anywhere if that is normal or not. There seems to be a lot of play in driveshafts/tranfercase and differentials. My next thing to try is to remove the front driveshaft and see if anything changes... Anyone have any experience with something similar? I really don't want to just start randomly replacing parts.

04-29-2012, 01:48 PM	#7
buckwill Elite Explorer trona calif 1998 sport Join Date: Feb 2010 Posts: 241 Vehicle Specs	if you have pulled the half shaft and turn the wheel and u can hear or feel anything the bearing is bad and needs changed,,should hear and feel nothing when bearings are good,, buck __________________ if my memory was getting shorter would i know???,, disabled viet vet, retired navy,, 98 exploder sport sohc 4.0,, retired macinist,gas and steam turbine millwright,, ive arrested, stroked twice and i mispell lots,

04-29-2012, 10:17 PM	#9
buckwill Elite Explorer trona calif 1998 sport Join Date: Feb 2010 Posts: 241 Vehicle Specs	andys auto sports 1-800-419-1152,,, ball joint boots for ford explorer,, in COLOR if u want!!!!buck __________________ if my memory was getting shorter would i know???,, disabled viet vet, retired navy,, 98 exploder sport sohc 4.0,, retired macinist,gas and steam turbine millwright,, ive arrested, stroked twice and i mispell lots,

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04-22-2012, 12:41 AM	#2
tlutz211 Wannabe Elite Explorer Houston, TX 1997 XLT 4x4 4.0 sohc Join Date: Sep 2011 Posts: 64 Vehicle Specs	Cv joint on front drive shaft where it connects to transfer case... Even if visually it looks sound, internally it could be fried... This fixed most of my problem with the same exact symptoms (cv joint $125 autozone special order) still have some growling though and and hoping that it will be resolved this weekend with new bushings for upper control arms and camber bolts (mine look fine but do have some play) also if you have done a torsion twist try backing down just a little.

04-22-2012, 04:27 AM	#4
tlutz211 Wannabe Elite Explorer Houston, TX 1997 XLT 4x4 4.0 sohc Join Date: Sep 2011 Posts: 64 Vehicle Specs	Ahh... Didn't pay attention to that... I have a bad habit of seeing someone with similar symptoms that I have had and just assuming they are running a comparable year model lol

04-22-2012, 01:58 PM	#5
calthaus Wannabe Elite Explorer Minnesota 2002 XLS 4x4 4.0 Join Date: Apr 2012 Posts: 5 Vehicle Specs (Original Poster)	Thanks for the quick responses. I pulled the front driveshaft, noise is still there at 60 on up. Put the rearend up on jackstands and ran it up to 30 then 60. Crawled under to listen closer and the noise is definetly coming from the differential/half shafts. Sounds like more noise is coming from the drivers side. After shutting down I checked the movement of the half shafts. The drivers side moves in and out much more than the passenger side. How much movement is normal?

04-29-2012, 12:36 PM	#6
calthaus Wannabe Elite Explorer Minnesota 2002 XLS 4x4 4.0 Join Date: Apr 2012 Posts: 5 Vehicle Specs (Original Poster)	OK, I pulled the drivers side rear knuckle and hub. How can I tell if the wheel bearing is bad? When I turn it, it does not "free wheel" and there is a faint noise like there is sand in the bearing. Should it spin pretty easily and keep spinning on its own for a bit?

04-29-2012, 09:50 PM	#8
calthaus Wannabe Elite Explorer Minnesota 2002 XLS 4x4 4.0 Join Date: Apr 2012 Posts: 5 Vehicle Specs (Original Poster)	I guess I am then getting a new bearing. I also managed to tear the ball joint boot worse than it already was whiltrying too remove the ball joint from the knuckle. Where the heck can I find a new boot? I have searched all over and no luck...

04-30-2012, 10:18 PM	#10
calthaus Wannabe Elite Explorer Minnesota 2002 XLS 4x4 4.0 Join Date: Apr 2012 Posts: 5 Vehicle Specs (Original Poster)	Thanks. I found a universal boot I can use for now till I order one up. I took the hub to my mechanic who said the bearing seems fine. Said to bring it up and they would put it on the lift and try to find the source. So I put it back together (which was much easier than taking it apart) and took it for a ride. Keep in mind I also changed the gear oil in the differential yesterday. It was dirty and a bit thinner than the new 70w-145 I added. Anyhow, I noticed a change in the symptoms... the noise now starts at 70 MPH vs 60-65. I also noticed that now when I run it up to 80 and get the roaring vibration, if I let off the gas the sound fades for a moment as it starts to slow than comes back. It also seems like after I let off the gas and let the sound fade then accelerate softly just before the sound comes back it also keeps it at bay for a moment.... slack in the rearend? Gears, bearings?