Bad Driveline Noise 96 XLT 5.0 AWD

[tgibbonsfordluv]

Sorry if this is a double post folks, I looked through about 15 pages and couldnt find a thread on it.

I'm getting a real hard clunking from the drive line on my 5.0 AWD. Sounds like its the front of the vehicle. All the front suspension parts are new as are the CV shafts. This baby has got 211k miles on her.

Sometime's if I accelerate very gently It wont make any noise. Otherwise it seems to do it in both 1st and 2nd gear up to about 3k RPMS and to about 45 MPH. It does it significantly less when the wheels are turned.

I'm guessing the problem is in the transfer case or the front diff. I'm gonna change the fluid on both of them tomorrow (and check for any metal shavings or signs of damaged parts) but I'm sure someone else out there has had this issue.

These T-cases are real pricey for a new one, even the viscous couple by itself is a huge chunk of change (more than I paid for the truck). I'd hate to start replacing stuff willy nilly and not fix it.

I'm a pretty well seasoned mechanic but don't much about these all wheel drive cases. If anyone had a schematic blow up of what the case looks like, I'd love to see it.

Thanks folks.

 

[FIND]

Check the bolts on your caliper brackets. Sometimes they work loose after servicing on these trucks.

Do all of your tires match in size exactly? All at the same pressure?

http://ww2.justanswer.com/uploads/s420/2009-11-05_152716_97_Explorer_AWD_transfer_case.pdf

Here are some exploded diagrams of the t-case

 

[tgibbonsfordluv]

Yeah, the tires are all the same size and psi. No real difference in tread depth either. (I already checked that) It's not the caliper bracket bolts either. This is not my first ranger/exlporer. I had them fall out on me on my last ranger, that's never gonna happen again, lol.

It's definitely in the drivetrain. I thought maybe it was ball joints (they were bad) but have since replaced them. I don't wanna jump the gun but it almost feels like a binding or something slipping and then catching, repeatedly.

Like I said, I'm gonna drain them both out tomorrow and see if my answer becomes more obvious. I'd really like some feedback from anyone who has had trouble with the T-case specifically and fixed it.

Thank you though, I probably would have told someone else to check the same things you just told me.

 

[tgibbonsfordluv]

Oh sweet, my eyes missed that you linked the diagrams. Thanks a bunch!

 

[Joe Dirt]

I had a similar issue with the TC in my '97 V8. Replaced it and the noises went away...

 

[1992fordgreen]

I had a similar issue with the TC in my '97 V8. Replaced it and the noises went away...

Don't think he had this on his mind to do...if anything, get a used one, from a pick a part place.

 

[tgibbonsfordluv]

Yeah, If anything I may go used. There's a real fine chance I'll rebuild the thing myself. Did some looking around and found the viscous couple for 270 at the cheapest.

While digging around on google, I found this thread on this page.

http://www.explorerforum.com/forums/showthread.php?t=225515

Looking it over along with the schematic posted above I got to thinking about the drive chain for the front output. I did notice when checking the u-joints in the front driveshaft that the front output shaft on the t-case will spin independently of the rear. Maybe a 8th-6th of a turn. I'm wondering if that chain hasn't stretched out and is causing some of my problems.


If I do try and rebuild it myself I have to deal with the truck being down while I have it apart. I'm sure it'll be more than an afternoon. Such as these things go. I'm sure once I get it apart I'll decide for sure which parts are gonna need to be replaced. Thinking about finding a driveshaft to stick in the rear to make it 2dw for a while, while the case is out.

 

[jremington59]

Pull the front drive shaft out and take it for a ride and see how it feels. That can at least help narrow things down a little. When mine went it was making an awful noise.

 

[tgibbonsfordluv]

I'll probably give that a go around just for grins. If I can rule out the front diff though, the next step will be a t case rebuild. I've kicked around the idea of pulling the front driveshaft until I can get the case straightened out but the "creeping" in park is unacceptable. I drive my truck for a living and park often.

What did you do to fix yours? I read a good thread in the transmission and transfer case forum about rebuilds, but that particular fella didn't have any problems with his viscous couple (that he knew of) so he didn't replace it. I'm kind of at a loss to decide if I should replace the couple or not when I rebuild. It'll save a lot of coin if I dont, but if it's seized up I'd really rather replace it. I can't seem to find any real great info on testing it. Two tests I've heard are to jack up the rear wheels and place 2x4 boards under the front wheels. Start the truck and put it in D. If it drives over them, the couple is seized. The other test is to get the real wheels in a high slip situation (like on ice) and have the fronts on good traction surface. You should be able to drive off the ice without issue. If it doesn't, the couple has blown it's seal and is free spinning (not engaging the fronts).

It's gonna be a while til I have any ice to try the latter test and idk if the first test is a good idea when I know the t case has other issues besides the couple.

 

[jremington59]

I'm betting the CV end of your front shaft has gone. Does it make different noises at different times? For a while mine was making this slapping noise when I was going down the road that you would have thought was in a rotor, lol. I got a hold of some guy in Jersey and he put me one together for a little over 200 if I recall.

I don't know whether it's true or not, but a mechanic at my local Ford garage told me that when the VC goes bad it will creep in park just like it would with the shaft removed. Your best bet is to pull that front driveshaft and see if that's what's making the noise.

 

[Joe Dirt]

If it was a new vs. used thought, I didn't put in a new TC. I picked one up from a yard locally with 66k miles and a parts guarantee, and installed it. $110 OTD, problem was solved...

 

[jremington59]

That was a super deal you got Joe.

 

[FIND]

Just saying, it's a great time to switch to a part time 4wd transfer case from an F150...

 

[Wolfrom64]

I just recently rebuilt the transfer case in my 96 5.0 awd the chain was extremely worn but the coupler was still good, parts ran me about $200.(a rebuild kit and chain). The noise sounded like it was right under the drivers seat. The 96 should have the 4 bolt front flange on the transfer case which is hard to find around my area.

 

[tgibbonsfordluv]

I don't wanna go to a 4x4 case to be perfectly honest. It's a street truck and I'm not in the least bit concerned about off road performance. I drive very fast and tend to do so regardless of pavement condition. I LIKE the way the AWD case responds in the wet and the snow.

Joe, you did get a real good deal on a used one. You don't live too far away from me, dare I ask which yard got you a deal like that? Did you have to pull it to get that deal or was that OTC?

You're kind of all over the place jremington. I can't in any way equate the sound to a bad rotor. It's a hard thunking. I did check the u-joints on the front drive shaft. I'm not feeling any play in them, though I havent ruled out the idea that they may be binding. I know a place in Chicagoland where I grew up that presses u-joints real cheap. I'm probably going to get them all done (front and rear) just because of the mileage. As for the VC, i could see it doing the slipping like that if it leaked. It's my understanding that they also freeze up (which is more common). Everything else I've found doesn't point the the VC being the case of the noise. I'm debating whether or not to replace during a rebuild anyway. If it's frozen, it would be hard to tell for sure. I don't *think* it's frozen though. I was driving in the rain on monday and really kicked it hard in the behind pulling out into traffic. I felt the rear tires start to slip and then the front tires picked up the slack. I can only guess it's still working as it should.

LJBex, that's almost exactly what I'm getting from mine. Is there any way to test the VC that you know of once the case is taken apart?

 

[Wolfrom64]

with the case apart it would be hard to do but if you turn to full lock like turning around and let off the gas it should still move through the turn and not bind up like when a 4wd truck is in 4wd if it does not bind up then it should not be frozen . my chain was so stretched that i could make it touch in the center while in the case and i only have 106 k mile on my truck. sounds like you should be fine with a rebuild and new chain. from what you said in your last post. also you will need to find out what chain you have in yours as in another thread there are 2 different ones. these are the 2 links to info that helped me .

http://www.explorerforum.com/forums/showthread.php?t=225515

http://www.explorerforum.com/forums/showthread.php?t=218430

 

[Wolfrom64]

here is a link to the rebuild kit i used they also carry the chains

http://www.ebay.com/itm/261077315440?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649

 

[tgibbonsfordluv]

Yeah, I've read both of those in detail. That's where I'm getting most of my info on it. I wonder though if it matters which chain you use. Sounds like one is just thicker than the other. I've got twice as many miles on mine as you do, but like I said from driving it in the rain the other day, it feels like the couple is still working.

Thanks for the link on the parts too. Now I just need to scrape together some money and time to do it. If I can find one as cheap as JoeDirt was talking about tough, I may just go that way. I did some digging online for used cases and most dealers were asking four times what he says he paid.

 

[Wolfrom64]

there is a difference in the chains not sure what but one is not interchangeable with the other the wrong one will not mesh with the gears correctly.

I searched about 4 u-pull-it yards around here and could not find the one for a 96 or early 97. the yards around here want 4 to 5 hundred, so i just decided to rebuild. it has been running great with no problems for over 1000 miles. so the wife is happy. she drives the explorer I have the 89 bronco II and a broke s10 ZR2 that is getting ready for a transmission rebuild. that is my next adventure.

 

[tgibbonsfordluv]

Yeah, that's what I kept seeing in price for them too. I'm probably gonna go the rebuild route. Is there any good way to know which chain you have without taking the case apart? I'd really like to order all the parts before taking it out. Like a vin code search or something?

And really? What do you want with that screwed over Isuzu S10 anyway? (Mostly joking)