Driveline Noise

[StuckInKentucky]

My '99 XLT (4WD 4.0 SOHC 5-spd auto) has a noise/vibration in the front end that we can't pin down any closer than it is somewhere between the tires and the transfer case. I always run it in 4-Auto . . . other than once every month or so I "exercise" 4-Lo in my gravel driveway (just to make sure everything is shifting OK).

As soon as I bought the Explorer in April, I had it serviced by a friend of mine and since it had over 110,000 mi. on it I had him change all fluids (front and rear diffs, transfer case, tranny, etc.) He commented that all the fluids he drained looked good and that he didn't see any evidence of undue wear - metal shavings etc. In addition, the truck received new lower ball-joints, a complete brake job (new rotors on front), and new shocks.

Life was good until about 6 weeks later when the passenger side front wheel bearing failed while I was on my way to work. This was replaced with a new one and I was on my way again.

Starting about a month later I thought I could feel something in the front end whenever I made a low speed left turn. It was really faint and, at first, I thought I was just overly paranoid (thinking back to the wheel bearing) but gradually it became more noticeable and really felt like something was rubbing . . . almost like the tire was rubbing while in the turn. Again, this was only when turning left. I had convinced myself that I had a bearing problem again (or bushings) when I noticed that if I let off the gas while turning, the vibration went away. The vibration could be felt through the steering wheel and the floor board.

Fast forward to the present, the vibration has become worse and is even audible at times. It is always when accelerating (even gradually) and nearly always when coming out of a turn to the left.

Finally I took it to the shop Friday and the owner took it for a drive. While I was in the passenger seat I could feel the vibration (faintly) in the passenger side floor board. When he switched into 4-Hi there was a very load moaning (whining, groaning?) sound from the drive train regardless of whether we were going straight or turning. He began to suspect the front differential and I asked him to check it out and see what we needed to do. When I checked back with him today, he was stumped. He said that the fluid levels were good in the diff's and transfer case and that he "fished" with a magnet and couldn't find any metal shavings other than a little bit on the rear diff drain plug magnet. He put the truck up on a lift and ran it in 4-Hi for a while but couldn't really hear anything other than with a stethoscope on the front diff and transfer case . . . but he couldn't pinpoint where the sound was coming from. After running it for a while he also checked for "hot spots" but couldn't find anything. In addition he checked the drive shafts and suspension parts and couldn't find anything loose.

Since differentials and transfer cases are pretty expensive to replace and then "hope" the problem is fixed I'm looking for help. Does anyone have any other trouble-shooting advice to help us track down the problem? Could the CV joints do something like this?

I've searched and found several other posts that described similiar problems but unfortunately I couldn't find one that reached a successful conclusion.

Thanks for reading and any help is appreciated.

Jim

 

[dmac0923]

The front CV joint is bad. CV joints usually only make noise when turning or when the suspension is flexing a little bit. the CV joint when taken apart looks like a combination ball joint/u joint. most times CV joints make POPping noises if they totally shot. but in some cases if the boot is ripped and some moisture has gotten inside and corroded the surfaces you can get rumbling noises.
save yourself the future trouble and replace both sides now.

 

[Dan Whitaker]

It's also very possible that it is your front drive shaft. It has a CV where it bolts to the t-case. I've been fighting an on again off again popping noise & viration since early May.

I had replced the drivers side axle shaft & hub bearing assy. It has ended up being my front d-shaft. There is a boot on it that is hard to see. Crawl underneath your X and feel around where the d-shaft bolts to the t-case & you will fill the rubber boot.

I'll bet you will find that it is torn. If so all the grease is gone & this is your problem.

 

[StuckInKentucky]

Thanks

Thanks for the replies.

I left the Explorer with the mechanic so that he could drive it some more and try finding the noise. I will go down there Monday and take a closer look at the CV joints.

 

[jackndelphine]

Hey did you ever figure out that noise in the front end of your X, I am having the same exact problem with mine, and I think it is the outer bearing on the differential that is bad.

Jack

 

[dynamite196]

i have the same exact problem, pretty sure it isn't a cv joint though cuz i pulled them and they seemed pretty tight (or do they go bad in some other way?) the vibration also goes away as the truck gets warmer

 

[Big6ft6]

Anybody figure this out yet? I'm having the same issues on mine, hub is new, cv joints seem tight...I'm scared.

 

[Turbo302]

I got the same issues on a 2000 XLS 4.0 SOHC Auto 4x4. 142,000mi

No major change turning left to right.

I thought it was tires, so we got brand new ones, still grumbly.

It has newer wheel bearings (changed 6mos ago in hopes to quiet noise, no change).

Has all new ball joints, shocks, tie rods etc...

The CV's look great, no rips, OEM Ford.

The front DS looks fine, no rips, OEM Ford.

Anyone ever solve this kind of issue? I have searched and searched but no one ever posted their solutions.

Any suggestions greatly appreciated...

Tim

 

[Big6ft6]

I still haven't solved the problem. I have rotated all my tires around and the noise still seems like it is coming from the front left in front of the driver. I only have a few option left. Since my tires are newer I don't want to buy new tires just to see if the noise goes away. So if I could find another explorer owner who would let me swap my wheels and tires with his and drive around the block I would know quickly if that solved the problem.

Otherwise I'm down to the axle bearings in the front differential..these are roller bearings that support the half-shafts where the enter/exit the differential...or if that isn't it.....I'm to the ring and pinion themselves.

I've gone as far as to remove my half-shafts from the differential and look at the roller bearings, they seem to move very smoothly...and I've removed my front driveshaft and it made no difference.

This noise has for the most part ruined my experience with this explorer. I loved my first two...but now this one has been a bad bad experience.

 

[Turbo302]

Still wondering if anyone else has solved their noises.

I went ahead and rebuilt the entire front differential with all OEM bearings races and seals... Noise still there

I even defected the two front bearing hubs with new ones even though they seemed smooth...Noise still there

It has gotten real real bad lately and is much louder when turning left. I can almost make it silent by turning right. This has always told me wheel bearing in any car I have owned, but 3 sets bad out of the box...I dont think so.

I am down to thinking CV Halfshaft, as this is the only thing in the front end that hasent been changed, and nothing has signifiantly made this grumble quieter.

Anyone have issues with CV halfshafts even though they look visually perfect??

SOMEONE PLEASE SHED SOME LIGHT!!! I have found others online that have had the exact symptoms, but have never come back to say what fixed their noise.

HELP!!

Tim