Drivetrain noise...Need help!

[djslcfr]

My son just bought a 2004 explorer and it drives like it's stuck in 4wd. It has a loud grinding noise and occasionally makes a "clunking" sound when driving. The dealer has replaced the u-joints, front wheel bearing and now says it's the tires. Does anyone have some advice or insight on this. It is on the verge of becoming a LEMON.

 

[rrgone]

The first thing you need to do is find out if it is indeed the 4WD system that is causing your noises. Your description does sound like that could be it. I would pull the power fuses for the 4WD system located in the junction box near the battery and see if the problem goes away. It won't hurt anything to drive it that way. Look in the owners guide for the fuse numbers and caution about working in the power box. In my 2002 there are 2 fuses, #17 and #18, for the 4WD.

Post back what you find out and we can go from there. It could well be the tires by the way.

 

[jqsford]

I had very similar sounding problem in my 2004 4x4. A lot of vibration and noise when on highway traveling at 40 mph plus. It all started after I changed out the front tires but not the back just a slight difference in tire diameter will make a huge difference. Also dont know why but when it rained it would make unreal noise clanking and grinding.

 

[stsmoker]

I also have a similar problem...if i were to pull the 4x4 fuses, would that hurt my awd system any at all??

 

[Rpalumbo]

2004 explorer

I am having a similar problem as well. I get a lot of "thumping" in the front of the vehicle when I let off the gas at speeds over 45 mph. It only seems to do this after 10-15 minutes of driving though. Once it falls below 40-45 the "thumping" goes away.

 

[Yellow Jacket]

'04 drivetrain noise

I also have a similar problem...if i were to pull the 4x4 fuses, would that hurt my awd system any at all??

I'm having issues with my '04. Lots of noise from front end. Replaced left front bearing/hub assembly and it didn't resolve. Will replace right front hub assembly this week.

Tires are OEM Michelin, all wearing normally, with 55K on the vehicle.

It sounds to me like the transfer case or front differential is making the noise, but from experience, the wheel bearings could be the culprit.

What is best method of eliminating/diagnosing this issue? How do I determine if transfer case is bad? How do I determine if bearings inside front differential are bad?

Thanks!

 

[HCCA 250]

I had a problem that sounds like what everyone is describing. Turns out it was the rear differential. It had only done it for a few days before I took it to the Ford Garage. It had already damaged the transfer case...or, so they told me. So, under warraty, I got a new transfer case, and they rebuilt my rear diff. Solved the problem, in my case.

 

[Yellow Jacket]

04 Explorer front end noise problem solved - front hubs

After changing the driver's side front wheel hub, and still having noise that sounded like either the front differential or transfer case was bad, I changed the passenger side front wheel hub assembly and that solved the problem. The SUV is now quite as a Lincoln.

The hub replace job is easy if you have: 1) a wheel hub puller!! Don't try this job without it! Why, because it allows you to push the front axles out of the hub far enough that you can get a shallow well 15mm socket with a power bar on the 3 hub retaining bolts. If you don't do this you'll be working way harder than you should!

2) 30mm deep well socket for hub nut

3) 14, 15, 18mm sockets

4) grease

5) permatex

6) torque wrench that goes to 184ft pounds for hub nut; 85 ft lbs for others

I'm so glad the noise is gone!

 

[Yellow Jacket]

Sorry to have hijacked your thread...

My son just bought a 2004 explorer and it drives like it's stuck in 4wd. It has a loud grinding noise and occasionally makes a "clunking" sound when driving. The dealer has replaced the u-joints, front wheel bearing and now says it's the tires. Does anyone have some advice or insight on this. It is on the verge of becoming a LEMON.

I hope you got things figured out with your 04.

...I guess I was so bummed about mine, I didn't realize I was hijacking your thread. Again, my apologies.