Intermittent noise while driving.

[j.hutton]

Greetings and Salutations, I have an intermitting rumble cluck noise present only after driving @ 6-8 miles, a bump in the road starts the rumble. You can feel it in the floor board,steering wheel,and the noise pronounces when alternating left to right also when going over a hump or dip. Make a hard l/r turn at slow speed noise vanishes. Suspect hub bearing just not convinced. Speed doesnt change noise. Have already replaced drivers lower ball joint. The rumble/clunk seems like a prop shaft vibration . Front shft is good,cv joints float w/ hand movement. Raise veh on lift there is no loose motion or worn or broken suspension items, struts not wet. Its really hard to describe and intermitting, but when it decides to rumble it pronounced in the left front.
Also the frt/rear diff are getting hot,almost to hot to touch.... any comments or suggestion welcomed Thanks Jody
the veh is an 2004 mountaineer awd

 

[Mayer1ab]

The slight rumble you are getting may be caused by a bad t-case motor/low t-case fluid. This (low fluid levels) may also explain your differential getting excessively hot.
Do you have a four or all wheel drive? I can give you more info if you give me year/engine/vin code (8th digit of your vin). Give me all you can and I will give you the best answer I have.

 

[j.hutton]

Thanks Mayer, the diff levels aand t/case levels are good. Althought the t/case is dark(burnt clutch look). The vibration is a phase 2, speed doesnt change the rumble, suspension movement does up and down. I have road tsted monitoring frt/reaf vss,surely the clutch pak wouldnt engage and disengage that harsh. The veh is a 2004 Mountaineer w/ no push button selector to awd,4hi, etc... Jody

 

[j.hutton]

Ill try to get the vin posted....thanks

 

[1Aauto]

welcome to the site.

Tony

 

[BrooklynBay]

Welcome to this forum! I've renamed your thread, and moved it into the stock 2002-2005 section.

 

[j.hutton]

Thanks Brooklyn,been a little while since on the site.The front diff was the problem,Dont know exactly what was causing the rattle/rumble but a j/yard unit repaired the concern.Now for question #2 My 2002 exploder is have symptoms of binding in sharp turns(just like when4x4 engaged) then pop, loud enough to make you get out and check for parts to be laying. You can disconnect the brown wire(to clutch) and symptom gone. After reviewing multiple threads Im leaning towards to viscous clutch. Although this is an awd(controltrac) veh , Im asking myself would the t/case have both.If it has a PWM elec clutch it shouldnt need a viscous. Maybe ive read too may threads and have confused me brain. So far ive replaced the gem module,two window regulators,wss in rear diff, rear diff brgs,transmission overhauled(plantery washer)lodged to tcc passage causing no lockup after doing solenoidpak and reman VB. And last but not least the timing chain cassettes are raising h ee double L. Thanks for all input..... Jody

 

[BrooklynBay]

It sounds like the electric clutch isn't disengaging completely.

 

[j.hutton]

Any info or does a visual inspection show failure... Monitoring dutycyle with handheld shows fluctuation in%%%. If i read it correctly it llike a A/c clutch applied with amperage not just off/on Thanks... jody

 

[BrooklynBay]

The internal clutch might be skipping since it's worn. A visual inspection of the inside of the transfer case is necessary. The other option is to keep the brown wire disconnected as you previously mentioned.