96 Aerostar. E-4WD jumping & popping while turning.

[zldavis]

My 1996 Aerostar has an electronic 4WD. Recently while making left or right hand turns while slowing down to about 15mph to turn the front end makes a violent jumping/popping/thumping which shakes the front end. After inspection of the front end we noticed a bracket was broken which connects to the transfer case. We had the bracket welded back together thinking this was the problem, but the jumping/popping/thumping continues. You can feel it under the drivers side. Also when you switch from drive to reverse, you feel a hard thump which seems to be related.

Has anyone had this problem or know what it might be?

 

[BrooklynBay]

Welcome to this forum! Did you check the CV axles, upper control arm bushings, tie rod ends, ball joints, and motor mounts?

 

[zldavis]

I checked everything except for the motor mounts.

 

[BrooklynBay]

Did you turn the wheel with the van on a lift to see if it still makes a popping sound?