AWD is making popping noises.

[OlBlue58]

I bought this 97 explorer a few months ago it didn't have a front drive shaft. I bought one got it installed and the front end started popping a friend of mine said it was the spider gears so I bought new gears and front axles because the old ones were leaking but after replacing all this it still pops or clunks and the front axle has been replaced does anyone have a clue as what to do on fixing the problem

 

[Turdle]

Transfer case-

 

[BrooklynBay]

Welcome to this forum! I've renamed your thread, and moved it into the stock 95-01 section.

 

[rock5b]

Does it clunk only in 4wd low lock on tight turns forward and or reverse? Or, does it do it in 2wd normal driving?

 

[OlBlue58]

it's a awd and it pops when turning or if I take off real fast and it seems like it's coming from the drivers side

 

[rock5b]

clunky front end

I have had mine for 14 years and has always done that. 220700 mile now. I got it with 81K. It has not got better or worse. seems like it is just a weird trait for this beast. I did a diagnostic on it and came up with the GEM needs reprogramming.?? It is a controller behind the radio. I talked with Ford about it and they said the reprogramming would not make it quit and that it was just the fact that the wheels are turning at such a different rate at tight turns that the trans case has to jump to catch up or lag back to make both sides equal. I have limited slip rear axle and does not do it at the back, only the front.
Maybe this info help to ease your thoughts.

 

[joecrna]

I vote for the center diff in your AWD not slipping enough or at all. Why was the front drive shaft out in the first place? Bad spiders ect in the front axle seems to suggest that binding in the drivetrain might have taken a toll. Again this all seems to suggest a bad center diff, its not a true transfer case as this is an AWD not 4WD vehicle, but it serves the same basic purpose.

 

[OlBlue58]

I was kinda thinking the same thing the front diff. being off center but theirs no shims to shift it from side to side and the front drive shaft was missing when I bought it back in feb. do you know if I can fix it by changing out the transfer case?

 

[joecrna]

Before just switching out the transfercase, I would first try to make sure that is indeed the problem. Take the drive shaft back out. Does the problem go away? You already repaired the front axle, correct? If so and the problem goes away with the front driveshaft out, i think you have found the problem. A bad center differential.