Another "clunker" '96 Explorer 4.0L 4X4

[traderalph]

My first post here. We have a "clunk" when first accelerating and a second
when braking. My son ignored this until the transmission went out. We
replaced the transmission, hoping that was the problem but it's still there.
The differential and universal joints look tight and the spline gears are cleaned and greased, leaving the transfer case. It's a "Control Trac". Could the
transfer case act like this?

 

[Vic_Ferrari2002]

Yes. Before long you will start to feel a thumping under the driver seat when you let off the gas while cruising.

At least that is what happened in my '97.

 

[traderalph]

"thumping under the driver's seat"

Did you fix the problem by replacing the transfer case?

 

[Vic_Ferrari2002]

Yes changing the transfer case fixed the problem.

 

[razo164]

I recently acquired a Ford Explorer Sport 4x4 that is showing signs of this clunk. If you come to a stop quickly it will clunk. If you come to a gradual stop no problem. I rarely get it upon acceleration.

I have researched the issue and found a tsb on Explorer/Rangers that states the cause of the clunk is the driveshaft binding. The cure is to remove the drive shaft and the rubber boot and grease the splines. I have read about it coming back after greasing as well. My Explorer runs like a champ so I will go for the cheap fix first and then worry about trx cases etc.

http://www.fordrangerforum.com/frf/...aft-slip-yoke-ranger-explorer-tsb04-23-07.pdf

 

[Vic_Ferrari2002]

Also had that symptom and greasing the splines helped very little but, since the transfer case swap I haven't had that issue.