"Clifford" The Big Red Truck | Page 3 | Ford Explorer Forums
  • Ford Explorer Community - Maintenance - Modifications - Performance Upgrades - Problem Solving - Off-Road - Street

    Explorer Forum Covers the Explorer ST, Explorer Sport, Explorer Sport Trac, Lincoln Aviator,
    Mercury Mountaineer, Mazda Navajo, Ford Ranger, Mazda Pickups, and the Ford Aerostar

    Register Today It's free!

"Clifford" The Big Red Truck

Possible vacuum leak. I found a line going nowhere on both sides. I can't find where they are supposed to be going however. This is just so fun, kinda like doing wiring is fun.
 



Join the Elite Explorers for $20 each year or try it out for $5 a month.

Elite Explorer members see no advertisements, no banner ads, no double underlined links,.
Add an avatar, upload photo attachments, and more!.





One on each side

PXL_20250629_192352706.jpg


PXL_20250629_192331276.jpg
 






On a side note, I'm hoping that if the vacuum leak gets fixed, my cruise control will start working. Hasn't worked since I got the truck!
Also, once I got the wheels up I turned the driveshaft several complete turns and didn't hear or feel any gaps or clunks that might indicate broken teeth. Still going to pull the cover for an inspection and fresh gear oil.
 






Doesn't answer your question, but you might think limit straps so full droop while under power, doesn't wipe a cv axle or worse. That may be what was going on cluunk noise.
 






traveler said:
On a side note, I'm hoping that if the vacuum leak gets fixed, my cruise control will start working. Hasn't worked since I got the truck!
Also, once I got the wheels up I turned the driveshaft several complete turns and didn't hear or feel any gaps or clunks that might indicate broken teeth. Still going to pull the cover for an inspection and fresh gear oil.
Click to expand...
I wasn't expecting a vacuum leak.
 






Turdle said:
Doesn't answer your question, but you might think limit straps so full droop while under power, doesn't wipe a cv axle or worse. That may be what was going on cluunk noise.
Click to expand...
Oh believe me that thought did run through my head. I've ordered new 4WD actuators (the vacuum activated part) to install tomorrow. I think that's the problem. According to my research it's a common problem exacerbated by water. And the dust covers on the hubs are rusty so I'm inclined to think there was water there at some point. The vacuum lines I discovered are actually supposed to have those open ends as vents, so they're not the problem.
 






Well, found a problem, let's hope it's the problem.
That gap that you can see daylight through isn't supposed to be there. That gap lets air through, and voila, no hub release. They actually make deletes for this part, that's how often they fail. But I'll go ahead and replace them and see how long they last. New ones are going in tomorrow.
The hubs and CV axles look good and feel pretty snug. Well, snug enough, they aren't brand new obviously.
With the exception of the 4WD actuators this set up isn't too different than the 2nd gen explorers. One notable exception. The CV axles are attached to the diff via large flanges similar to the one that attached the driveshaft to the rear end. It looks like it'd be possible to remove the front diff assembly by just unhooking the driveshaft, the two CV flanges, then unbolting the diff from the frame and lowering it. Nice to know just in case.

PXL_20250629_222111836.jpg
 






Well, just for kicks and giggles I pulled the diff cover. The oil was smelly (as expected) but clean, not sparkly, and the gears looked fine. I took the opportunity to clean the cover pretty well and I'm gonna paint it bright red (Cause that's the color I have on hand). I'll replace tomorrow once I get some new gear oil.
 






Well, the actuators were a problem, but not the problem. New ones are on and they still won't activate. The hubs are always engaged. And the CV axles sound terrible so they're getting replaced. I bought a new 4wd vacuum solenoid, perhaps that will get the hubs disengaged. So the CVs are coming off today and new ones on tomorrow.
 






I've decided just screw it. While I've got it apart it's getting all new hubs, actuators, and CV axles. We've got plans this coming weekend anyway so I'll get it buttoned up tomorrow. The passenger side hub was literally rusted in. I had to use a hammer to get it out, then an abrasive sponge to get the surfaces cleaned up.
 






Well, this is a testament to my inability to properly diagnose a problem. I put all new hubs and CV axles in the front, I inspected the differential. And as I'm backing out of the driveway I'm greeted by that same screeching, grinding noise. BUT this time I'm right next to the Explorer which acted as a "sounding board", sending the echo of the sound back to me making it easier to determine where its coming from, other than just under the truck. I've got loose parts flopping around inside the transfer case, getting ground up into smaller parts, I'm sure. I found a Transfer case on Facebook marketplace for 150, so I'm pleased that it isn't going to be that expensive. Now need to see if I can recruit my Stepson and nephew to help be bench press the old one out and the new one in. Also, the new 4WD actuators still aren't disengaging. I replaced the vacuum solenoid and the Vacuum check valve for them, and still nothing.
On the plus side, I've got all new parts in the front, so won't have to replace those for a while.
 






This reminds of the joke where the guy is concerned about his wife slowly losing her hearing so he consults his doctor. Doctor said to test her to determine how bad it is, when you get home ask her what's for dinner from 30 feet away, if nothing, then 20 feet away, etc until she hears you. So he does that when he gets home. Honey, what's for dinner at 30 feet, nothing, 20 feet away, what's for dinner? Nothing so he asks 10 feet away and she says for the third time chicken.

I'll search for some diagrams for the hubs.
 






Thanks for the joke... I needed it.
 












Well, after all this time, to listening to the noise, replacing CV axles, hubs, vacuum hub locks, even the transfer case, I'm embarrassed to announce that I found the problem. Yesterday lifted the rear wheels off the ground, then opened up the rear diff (I was pretty sure it wasn't the problem but wanted to be thorough). As suspected the diff was just fine, even the oil looked clean. I put it in neutral and manually turned the wheel to look at the gears (I should have done this a lonngg time ago). It was then I heard the noise from the source. The right rear wheel. I pulled the wheel, all looked fine. I pulled the rotor off and EVERY part of the parking brake fell to the ground. What was left of springs, cables, adjusters, shoes, pins, fell out on the concrete. I was at once joyful (that's the problem!) and very disappointed in myself. I had broken my #1 mantra. When in doubt, check the cheapest, easiest possible problem first. I have all the parts to fix it, but the caliper bracket/backing plate is missing a chunk of steel and I haven't been able to find one yet. So I replaced the rotor, brake caliper, and wheel so the truck is drivable now. Just sooo ticked I spent all that time and money replacing parts that were good. I suppose I should look at it as "I've got spares now!"

PXL_20250823_225247017.jpg


PXL_20250823_225252797.jpg
 






Oh yea! Still get the vacuum operated hub locks to work.
 






traveler said:
Oh yea! Still get the vacuum operated hub locks to work.
Click to expand...
I'd count that as a win. Based on the way you described it, I wouldn't have thought it could have been at the rear axle.
 






Yea, I know. I really didn't think it was either. But figured sure as the world if I didn't at least look at it.... LoL
 









Join the Elite Explorers for $20 each year or try it out for $5 a month.

Elite Explorer members see no advertisements, no banner ads, no double underlined links,.
Add an avatar, upload photo attachments, and more!.





Holy smokes

Noises are such a pita to pinpoint
Often the only way is to run the truck on the lift or on jackstands
Fun! But also dangerous. I always point the vehicle away from the house when doing this just in case lol lol
 






Explorer Features

Featured image Featured image Featured image Featured image Featured image Featured image

Explorer Features

Featured image Featured image Featured image Featured image Featured image

Featured Content

Back
Top