1999 Ford Explorer Sport - Transfer case issue?

[mwarren03]

I was recently experiencing some bad vibrations and a metallic clank coming from directly beneath the drivers seat. I got underneath and saw that the CV joint going from the front drive shaft to the transfer case was torn up. The drive shaft wasn't even connected, basically just rotating in the joint causing the metallic clank and the vibration at higher speeds. I replaced the CV joint, as well as the u-joint at the front of the drive shaft. Went for a test drive and all seemed well. All of a sudden I started experiencing an extreme knock/vibration/I don't really know how to accurately describe it, seemingly coming from the transfer case. I can't go more than 10 MPH without it kicking in and I'm too afraid to go any faster than that (it feels like my truck is about to explode). Is my transfer case shot or is there something else I need to check?

 

[RangerX]

Welcome to the forum!
I don't know if your Tcase is shot, but I suggest removing the front driveshaft completely and then test driving.

 

[imp]

+1.

 

[mwarren03]

Thanks for the reply. When I got home last night I drove it some and the clunks and vibrations weren't nearly as bad as they were the night of my first test drive. I dropped the drive shaft and the boot on the prop shaft I had just installed Friday was already completely torn. I haven't driven it without the driveshaft but I would put money on it being bad. I've got a new one on order, gonna put it on tomorrow night and see how it goes.

 

[mwarren03]

Replaced the Front drive shaft and the major knocks are gone. Went ahead and replaced the CV axles and hubs up front and now it's running great.