Clunking & Bad Gas Mileage (Help) Please !

[~Ray~]

I have a 95 Explorer with 6 Cylinder & 4wd.


Here's the Problem,
A few months ago I started noticing a clunking from the front axel when you first get going for a few miles "especially happened on cold mornings". At first I thought it was my brakes or a rotor or wheel bearing or something butsoon found out it was the 4wd actuator or whatever it's called that bolts on the front axel it'self "that has 2 vacuum lines & a plug going to it" & then then a few weeks later I start getting really bad gas mileage "like 180 miles per Tank" & check engine light comes on "1 time" checked code turns out to be EGR not Opening & Closing Properly. ps: I also have 2001 Explorer 16in wheels on my 95 how much would that make a difference?

This is what I have done so far,
I immediately thought Vacuum Leak So I start checking vacuum lines everywhere with with a vacuum guage & at all lines check out to 22lbs vacuum everywhere, is 22lbs the right ammount I'm supposed to have ?

I pulled the IAC cleaned & checked sliding mechanism, I just recently before put new plugs, wires, fuel filter & o2 sensors in, I cleaned the maf sensor element & reset the computer unplugging the battery.

Anyone have any suggestion of what I should try to do next or know the answer to this or any of my questions above ?

Edited: Also when I switch to 4wd to stop the clucking long enough for the motor to warm up sometimes it won't switch & the 4wd lights start flashing.

 

[No1dan2001]

Im not a mechanic, but in all of my surfing this site, and problems with mine, you might want to check the transfer case..well at least for theclunking. how many mines do you have? my transfer case crapped out at 146k. The wheels wont make any difference, because the 16 inch wheels will probably have lower profule tires than the 15's so everything equals out to about 5% of factory. Best of luck.

 

[No1dan2001]

PS> if it is I bought mine from http://www.jasperengines.com ...it was somewhere in the range of 1700 and we and uncle (Mechanic) put it in in about 4 hours.

 

[~Ray~]

Well the transfer case may be going out but what about the 4wd Actuator or whatever it's called on the axel that's not completely dissengaging the axels & the poor gas milage ?

 

[No1dan2001]

not too sure bout either...i would suggest a seafoam and a maf cleaning for the gas? maybe a new air filter and plugs..a general tune up
?? i dont know but if you figure it out letg me know...you might also wanna think about resetting the computer.

 

[~Ray~]

As stated above I have already cleaned the MAF sensor element & reset the computer.

I think my gas milage is alittle better now, not sure yet still haven't hit a half a tank yet but I'm already well over 100 so far only time will tell.

 

[~Ray~]

Welp I'm @ 240 miles & @ the top of the E so it looks like I might of fixed the gas problem. I got 16in 2001 wheels on my 95 so does that sound about right ?

 

[Doubt Incarnate]

your 4x4 system has a disconnect for the front shaft, and hubs i belive. the bad gas milage could be because your front drive line is engaged all the way up to but not including the hubs. in effect everything is spinning as if in 4high, just not actually the wheels. to me it seems you need to check out the connections to the vacuum disconnect real good. that seems to me to be the the part to start with

 

[~Ray~]

Well it appears I've fixed the bad gas mileage problem but what about the clunking I keep hearing sometimes when I fist start driving it, it stops if I turn the 4 wheel drive on while driving but most everytime my 4 wheel drive light starts flashing or it does not go into 4x4 any ideas ?

 

[~Ray~]

Well I definately fixed the gas mileage problem & I ruled out the 4wd vacuum actuator anyother suggestions why the clucking in the front end when ever it's cold & I first drive it the first couple miles ?