Horrible thumps and clunks in the transfer case

[DavidjAdams]

Hi every one

I don't like my chances but I am hoping that I can get some good news. My problem is when I switch into high or low 4WD it can take several attemps before it will enguage and when it does it can take longer to disenguage. Also when in 4WD I get horrible thumping noises as if it is jumping in and out of 4WD. This also happens when I start off in first with the 4WD switch on Auto when the car is under a small load. I hope someone can give me some good news I would hate to think of the cost of a new transfer case. (96 XLT)

Thank you
DavidjAdams

 

[PDExplorer]

happens with every explorer, try making a turn with the 4wd engage on dry pavement. sounds llike the car is falling apart. According to Ford this is "Normal". I went back under warranty work to ford and they replaced my transfer case and installed a "kit" which i was told wasnt under warranty, more of an aftermarket ford kit. but they did it for free. So the clunking and viscious banging is normal because the wheels arent slipping ford says, but im not sure about your slipping in and out problem.

 

[exploded99]

If it does end up being your transfer case, you should check e bay for a used one for your truck. You can find used ones with 75 to 90k on them relatively cheap, or you can buy a rebuilt for a lot less than the dealer.

You may want to post your question down in the transmission and transfer case section.

 

[DavidjAdams]

Thanks everyone for your quick replies. I got under to check out if there was any movement in the universal joints but they seem to be very good, but what I did find is that I can move the tail shaft ( not sure what it is called in USA maybe drive shaft) and found that there is a movement of about 2 or more inches turning it anti clock or clock wise plus 2 to 3 milimeters vertical movement. I would say according to the vertical movement I will have to replace the rear bearing at the very least and while I have the transfer case out I can suss the rest out.