Clunk on take off only

[jremington59]

An AWD is always AWD. There's no 2 WD to it. When you pull the front shaft it becomes only rear wheel drive because the front diff isn't being powered.

 

[98ExplorerGuy]

My 1998 Explorer XLT just turned 200,000 on the odometer. Three times in the last 15 years I have had the "clunk" problem and each time it turned out to be a shot transfer case.

I am currently about two years into my second "junkyard" transfer case and driving clunk-free.

 

[PFA]

I am having a sim issue with clunking. I am thinking the transfer case. Is it a big deal to remove the front driveshaft or pretty straight forward? How about the transfer case? Big job or just a couple hours?

 

[Wolfrom64]

Had the same problem with my 96 5.0 awd rebuilt the transfer case including a new chain fixed it. the chain has probably stretched and is slipping during acceleration.

 

[PFA]

What does it take to rebuild the transfer case? Just new chain setup? I have a spare transfer case from a wrecked EX that I parted out. Are the parts sold at Ford only or can you get them from an Auto parts store?

 

[masospaghetti]

Here is a bearing/seal rebuild kit, to do a full rebuild you will also need a chain.

http://www.americanpowertrainwarehouse.com/servlet/the-645/BW4404-transfer-case-rebuild/Detail

I have the same clunk with my 96 5.0, my front output flange on the transfer case has some fore-aft play that I think is the cause but I haven't torn into the case yet to see what the cause is.

 

[exlporer]

perfect time to do the 4406 swap. mine clunks too. 5.0 awd. new front drive shaft, cv axles, wheel bearings in the past 8000 miles. I need to check the mounts too..

 

[PFA]

What does the 4.0 SOHC have for the transfer case?

 

[fast_dave]

Did you check for loose or dry slip joint in the rear driveshaft?

I like this diagnosis because it's easy & cheap.

This part is almost always dry, and if it's not the source of the noise, well, you can always work your way up the $$$ slope

Remove one of the steel bands that holds rear driveshaft slip joint bellow in place, push bellow forward, and liberally grease slip joint. Pull bellows back to former position, and zip tie in place.

 

[Blueskeys]

Update. After less than 1000 miles the clunk got worse. It would clunk several times
On take off and sometimes coming to a stop. Took it to my tranny guy and his
Diagnosis, clunk IS the chain in transfer case. So the best solution is a rebuild of
Transfer case and tranny. I am now waiting on him completing the job. Or should
I say anticipating the BILL. Either way I hope it's good for at least 60k

 

[wollimann]

Hi guys,

i can confirm, that one of the Explorer 97 4.0 sohc clunks is gone after rebuilding my sparepart TC BW4405 w/speedo (thanks for the TC rebuild thread). But there is still one more clunk left, comming from tranny while it's shutting down in low speed (with deactivated AC).

Other clunks came from worn out prop joints (front driveshaft TC out), worn out front drive axle joints, worn out differentials, defective wheel hubs and so on.
Starting on and on to fix these problems, makes you poor.
I gave up making me crazy about these clunky sounds.
The Explorer is a trusted friend, which brings you where you want.

Greetz

Wolfgang