What I found to be the problem...
Well, here is my update.
I found that the front CV axle was not the problem. Even though the sound comes from the driver's side wheel area.
One month ago, 1300miles ago, I had this problem that sounded like the CV axle was going out. I took it to a Midas shop, they looked it over for free. The informed me that the front axles were fine and showed me the noise was from the transfer case area. Ok, I then took it to the Ford house(big mistake). They informed me that the transfer case was messed up and they wanted to replace the unit. About $1900 total bill. I told them no. I could find another t-case cheaper than that. They wanted $1450 just for the t-case. I found one for $850 new. So in the process of finding the correct t-case, I had picked up the t-case from the Ford house, along with the driveshaft going to the front diff. I had to show the parts place what the output shaft looked like on the 97+ part.
So I got curious one night and decided to take apart the t-case and have a look inside. What I found was, nothing wrong. This is where I got mad at the Ford house. Just some gears and a chain inside. Everything looked A-OK. Or at least to me it did. So I concentrated on the other part I had, the driveshaft. On the front end, it has a u-joint and on the rear where it attaches to the t-case, it has a CV joint. It did not move as smooth as it should be and even would bind up. I took the part to another Ford house and they agreed that the unit should be free flowing when moving it in any direction. So we ordered a new driveshaft. This fixed the problem for about a month or 1300 miles.
Now my CV popping sound had come back. So I decided to take a look at the stuff myself. Not really wanting to pay the Ford house another $389 to be a 'parts changer'. I took the t-case out and it looked fine. I had taken the driveshaft off, but didn't really pay it much attention, I just replaced it, it should be messed up. After the t-case looked ok, again, I turned to the driveshaft and it was not smooth anymore. It was binding up as before.
So maybe I got a bad unit from Ford, it happens. They are going to replace the driveshaft. 12,000 mile or 1 year warranty. But will this fix my problem? I wasn't so sure. I don't want to replace this thing several times till I get a good part.
There is a shop in town that sells a replacement driveshaft for this vehicle. It has the u-joint at the front as it should, but they have changed the CV joint to a u-joint at the rear as well. It is a custom made piece that bolts up directly to the t-case and all. I don't know if the local shop actually makes this piece or if they order it from some where. They had it in stock.
I have put this peice in the vehicle and the problem has gone away. Now, only time will tell if this is better or not. Most people say a u-joint is better than a CV joint. I do know that the u-joints are a whole lot cheaper to replace.
Sorry this post was so long, but I needed to let everyone know what my problem was, incase you are having the same problem.
So, if anyone needs a new driveshaft, I have a new one in the box from Ford. I am willing to sell it. I paid $170 taxes and all.
Or, if anyone needs the number to the shop where I got the custom replacement, I can send that to you.
