94 Explorer Manual Transmision problem

[Maxine Houghton]

Long post - sorry but there's a story to my problem ....
It began 6 weeks ago with a slight clunk from underneath (sounded as tho it came from the middle or rear) then a loud whine as I drove along straight. When I pulled over, dropped into neutral, engine running, it went away.

Within the week it worsened - pulling over didn't stop it - the only thing that did was turning another corner and
getting the clunk (reversing what was out of whack?)
When I finally got it to happen for my mechanic, he checked steering, transmission, 4x4 hubs...one thing he did was to replace the driver side front wheel bearings which were shot. His thought was that the 4x4 was engaging without "permission", perhaps because of the bearings being so badly worn. The 4x4 hubs were fine.

For 2 whole weeks the car drove like a dream. Now the problem is back, intermittent but almost daily. One thing that stops it is to pull over, & flick the 4x4 switch on and off.
The car doesn't drive as if it's in 4x4..it feels "normal" through the sterring wheel and wheels, and doesn 't sound like it's in 4x4 either.

There's almost always a clunky noise like something shifting and there's always a whine and a roaring noise which sounds like something isn't quite engaged.
During all of this the car is entirely drivable and there's no perceived performance degradation.
It's always when turning right or left in low gear, doesn't seem to matter if the car's been running 2 mins or two hours, cold or hot.
It happens when reversing or going forward when turning. On average, it's once a day.

It definitely seems to be engagement of the 4x4.

Does anyone have any ideas what this might be?

Maxine
94 Explorer Sport named "Stanley", manual transmission

 

[JDraper]

With what you described, it say its' a high probability that the auto hubs have gone bad. This is a very common problem on the older Explorer's. Best thing to do is replace the hubs with manual hubs from Warn or Explorer Pro Comp. do a search here on manual hubs, Warn Hubs, or Pro Comp Hubs, and you will find lots of info.

Good luck and welcome to the board!!!

 

[Maxine Houghton]

Thanks v much for the speedy reply. I'll check asap with my mechanic about this as a likely candidate as I'm due for a service about now.

Are we talking a long complicated job? If it turns out to be the problem, I'm wondering how long "Stanley" will be in the shop and what kind of repair bill I face.

Glad to join the club - I love my truck and it has earned its keep over and over again....Maxine

 

[JDraper]

Changing hubs is actually pretty easy. Anyone with a slight amount of mechanical ability and the right tool can do it at home. Took me about 1.5 hours to do both in my garage when I had a '92 X. Hubs ran just under $200 USD with the washer kit. There is one special tool you need, but it's only about $15 USD at any parts store.

 

[Maxine Houghton]

Thanks, guys. I stopped by my mechanic's last night to discuss with him. He had from the start thought the hubs were the problem, and had taken them apart to inspect. As they appeared to be ok he cleaned, greased, and put them back in. Might this explain why the car then ran fine for a couple of weeks - the act of cleaning and greasing did some good for a short while?

Perhaps you can explain what "goes" in a hub that isn't obvious to the naked eye?

I'm also interested in the replacement of autohubs by manual - Ford didn't recommend that. What are the pros and cons?

I notice that posts say the hubs are a problem in older Explorers...did Ford do something to the design or manufacture in the later models?

My mechanic can replace the autohubs in an afternoon for around Cdn$1000 most of which is the cost of parts.
So, new auto vs manual? I want to make the best decision for "Stanley" as we plan to be together a long time.

thanks much...maxine

 

[Maxine Houghton]

One other thing...anyone know to whom at Ford I write and complain about having to replace the hubs? My truck is 7.5 years old and has only 110,000 km (70,000 miles?) on it. It has been meticulously maintained for every service according to dealer specs. These things are supposed to be rugged...I don't consider replacing hubs after 70,000 miles a sign of ruggedness.

This kind of thing affects the family decision whether or not to go with a new Explorer (they want something newer with 4 doors and better back seats). With all the bad publicity about Explorers and SUVs in general, I'm under some pressure to replace Stanley with a sedan.
cheers...maxine

 

[TPLYNCH]

Maxine, unfortunately the hubs on the '91 to '94 Ex were a major weakness (along with the transmission, but that is a different story......) Anyway, they are no longer used, so would not be a problem with a new Explorer. As for CAD1,000 to replace with manuals, that seems a little steep, even with the current exchange rate. Try and get the parts from FordPartsNetwork or your local autoparts place. Shouldn't be all that expensive.....