8.8 Rear end noise?

[JohnH55]

Hey guys, my 2001 Explorer Sport is sitting close to 290k miles. I've recently noticed a clicking/ rotation noise when driving coming from the rear of the vehicle. I replaced both front wheel bearings after finding one was bad, which made this newer noise more noticeable. I don't believe it's brake related as I've deleted all the parking brake parts other than the cables. Those had previously caused noise after coming loose.

Here is what it sounds like with the rear end jacked up and in first. The sounds completely different than it did the last time I had the rear in the air. Coasting sounds particularly bad.

Is my old 8.8 finally needing rebuilt?
(U-Joints are Newish ~3-4 years old and don't have slop)

It appears that the output flange on the transfer case to the rear can move up and down/ side to side. I'm guessing that's not a factory option...

 

[C420sailor]

Is the diff leaking at all? If the pinion bearing is going, the seal will usually leak from the extra play.

I’m not smart on how much play is normal at the TC.

That all said…at 300k you’re likely due. I somewhat recently rebuilt mine at around 325k I think. Bearings needed replacement, but the gears still looked fantastic. It’s not a bad job if you keep your existing gears or replace your stock gears with Ford OEM gears. If you go to aftermarket, you get to play the shim guessing game.

I have a thread on my job…let me know if you can’t find it. It’s wild how much quieter a rebuilt diff is…..

Edit: Rear Diff Rebuild Parts

Here’s the link, if it turns out it’s time

 

[Turdle]

That sounds like the front end of drive shaft , u joint area, hitting the plastic fuel tank protector dealio right beside it. Noise is drive shaft speed.

If it is, a new transmission mount will put it all back in alignment

Edit. Sharp right turn will cause the above noise to get louder, sharp left may cause it to lessen.

 

[JohnH55]

Is the diff leaking at all? If the pinion bearing is going, the seal will usually leak from the extra play.

I’m not smart on how much play is normal at the TC.

That all said…at 300k you’re likely due. I somewhat recently rebuilt mine at around 325k I think. Bearings needed replacement, but the gears still looked fantastic. It’s not a bad job if you keep your existing gears or replace your stock gears with Ford OEM gears. If you go to aftermarket, you get to play the shim guessing game.

I have a thread on my job…let me know if you can’t find it. It’s wild how much quieter a rebuilt diff is…..

It was leaking a good amount normally for a year but it stopped 2 months ago (it is still full on fluid). I felt like that was kind of a bad omen.

 

[JohnH55]

That sounds like the front end of drive shaft , u joint area, hitting the plastic fuel tank protector dealio right beside it. Noise is drive shaft speed.

If it is, a new transmission mount will put it all back in alignment

The shield is still mounted good, and the driveshaft isn't contacting anything. The noise at 3/4 through seems to be in the rear diff. I don't know could that be the spider gears since only one tire is spinning? I don't have a position, it's and open diff.

 

[JohnH55]

I'm going to have a shop diagnosis the drive line. I already needed them to check my transmission (2-3 slip, I'm not confident working on it myself), so having them check the T case & Rear Diff at the same time is not big issue. Depending on what they say I may be in for a rebuild on the diff or T case.

 

[wollimann]

Maybe the universal joints are dry, if there is a red dust around the caps
the joints are dead.

 

[JohnH55]

I had a shop look at the Explorer, they said the chain is rattling in the T case and want 3000 for a reman and install. I'm guessing I can rebuild it for cheaper myself.

 

[C420sailor]

3000 for a transfer case job?!?!?!?!?!?!?!?

That sounds like a “we don’t want to do this job” price

 

[Turdle]

That price is ridiculous.

 

[JohnH55]

Yeah it's crazy, I could rebuild it for 200-300, and get a shop press for 1/6 of the price. Also my transmission 2-3 slip according to them is due do a leaking pan gasket...

 

[Josh P]

Yeah it's crazy, I could rebuild it for 200-300, and get a shop press for 1/6 of the price. Also my transmission 2-3 slip according to them is due do a leaking pan gasket...

ASE stands for ask someone else. Shops like this are why people say stuff like that.

 

[JohnH55]

Alright Guys, I bought a used T-Case shipped for $472 with only 37k on it and a one year warranty. I thought over rebuilding mine, but I have another project I'd rather put that time into. That other project being a D60 swap on my 91 F250, which I'm quite excited for. I'll update once I'm in procession of the new to me T-case, and after I get it installed.

 

[Josh P]

Alright Guys, I bought a used T-Case shipped for $472 with only 37k on it and a one year warranty. I thought over rebuilding mine, but I have another project I'd rather put that time into. That other project being a D60 swap on my 91 F250, which I'm quite excited for. I'll update once I'm in procession of the new to me T-case, and after I get it installed.

What powerplant is in the 250?

 

[JohnH55]

What powerplant is in the 250?

7.3 IDI, quite different from the 4.0 in my explorer.

 

[Josh P]

7.3 IDI

I like that body style. A ZF6 behind it would be a blast rowing thru the gears

 

[410Fortune]

ZF6 blah
I have 97 Powerstroke with zf5
To convert to zf6 would require
Transmission hump Modifications (sheet metal)
Install trans cooler and lines
New front and rear driveshafts
Transmission mount custom

The benefits? A second, second gear.
First gear and overdrive are same ratios as the zf5 …. So it is literally not worth all of that effort

 

[JohnH55]

ZF6 blah
I have 97 Powerstroke with zf5
To convert to zf6 would require
Transmission hump Modifications (sheet metal)
Install trans cooler and lines
New front and rear driveshafts
Transmission mount custom

The benefits? A second, second gear.
First gear and overdrive are same ratios as the zf5 …. So it is literally not worth all of that effort

But running through 6 gears is more fun than 5. Although if I was doing a trans swap it would be to a 13 speed.

 

[Josh P]

But running through 6 gears is more fun than 5. Although if I was doing a trans swap it would be to a 13 speed.

A road ranger would be a cool swap. 18 speed would allow high and low range to be split. Add a 2 speed rear axle.

 

[410Fortune]

I wanted to want the zf6 as my stepson found a 7.3 one in the yard and brought it home…. Then I did the research and was like oh dang
They sold it for $1500 next day

I should have as my “rebuilt” zf5 grinds going into 3rd

18 gears and a 2 speed rear end now we are talking!