Loud popping noise from front end

[Dan Whitaker]

I have a '97 Mountaineer & I am at my wits end.

Back in May with around 179,000 miles I replaced the left front axle shaft as it was making a popping sound at all speeds & when I made a turn in either direction it would get louder & the noise went away.

Then it started making the same noise again the first weekend of July.
The axle shaft had a lifetime warantee so I took it back to O'Reill'y's where I got it from in May & got a replacement.

I had the guy check my hub assembly as well because he thougt the shaft was not bad but said the hub felt fine to him also.
He thougt it could be the right side axle shaft I was hearing because sounds can be deceiving.

He went ahead & gave me a replacement shaft & again the noise was gone

Yesterday it started making the exact same noise again Six weeks after I replaced the replacement axle shaft.

I went back & got another axle shaft & of coarse the grilled me since this was my seond warantee replacement.

Well this time the noise did not go away

My wife thinks the noise is coming from the right side. I swear it is coming from the left side.

I don't think it is the hub assembly as I can not feel any rough spots and it is not making a grinding/whining sound that a bad bearing usualy makes.

Since I have not replaced the right side axle shaft do you think it could it or the right hub assembly making the noise?

I do not want to throw money at my Mountaineer and still have the same problem.

I have parked my Mountaineer for now until I can figure out what is wrong & I am begging everyone for thier thoughts & expertise.

 

[Turdle]

I have a knock that I have narrowed down to this
http://www.explorerforum.com/forums/showthread.php?t=159065&highlight=torsion+key+plates

 

[Dan Whitaker]

Thank's for the reply Jon, but I'm sure it's in the drivetrain.

If going 5 mph or under it pops about every 1/2 revolution of tire rotation.
25 mph+ it is a constant popping clattering noise.

 

[dogfriend]

Ring Gear?

 

[Dan Whitaker]

If it was the ring gear I would think the noise would be constant.

I'm thinking it could be u-joints but again why would the noise come & go?

 

[dogfriend]

CV joint on the front driveshaft?

 

[Dan Whitaker]

Does anybody else have some ideas before I start tearing apart my front drive train?

I'm begining to wonder if I got another bad rebuilt axle shaft.

 

[explrths]

I had the same problem. Couldnt find the noise until my hub bearing blew apart about 2 hrs from my house. It was really inconsistent. Its not to hard to check, just pull every thing off( 7 bolts including wheel lugs ) and try to turn by hand. If it feels sticky or kinda grindy. its bad

 

[Dan Whitaker]

Yea the 3-4 times I have had it apart & spun the hub it has definatly felt sticky. It doesn't feel grindy & that's why the the guy at the parts store & I thought it was ok.

I take it I should replace both hubs at the same time?

 

[dogfriend]

They cost over $200 ea.

 

[Dan Whitaker]

I can get TIMKEN hubs from Autozone for $160 ea. Timken is what the OEM ones are. I might as well replace the right side axle shaft while I'm at it.

So I'm looking at $400 worth of parts
The Mounty will have to sit until October since I won't have the money until then to do it.

 

[dogfriend]

There is a thread somewhere where someone pressed the sealed bearings out of the assembly. I can't find it now, but if I do, I'll post the link. It is much cheaper to just replace the sealed bearing, but you need a big press to push it out.

Part of the reason the hub assembly is so expensive is because it also includes the sensor ring for the ABS.

 

[Turdle]

I am not sure of the quality, but hubs are all over e-bay for 95 plus shipping, with abs sensor

??????

 

[Dan Whitaker]

I'll gladly pay the money for quality bearing hubs.
I have worked for a company for 17-1/2 years (IBT) which is an industrial supplier.

Those $95 hubs probably have China, Russian or Czech made bearings.
TIMKEN is one of the best in the tapered roller bearings bussiness.

 

[Turdle]

What about this?
Am I reading from earlier post it can be replaced?

http://cgi.ebay.com/ebaymotors/NEW-...tegoryZ42614QQihZ013QQitemZ230018686203QQrdZ1

 

[dogfriend]

I think that Ebay item is for a 2wd. I think Ford only sells the complete assy for the 4wd.

I do remember seeing a thread a couple of years ago where someone claimed that they pressed out the bearing separately and just replaced the bearing with the equivalent part for much cheaper. I can't find the thread now. I found some other threads where it was also discussed, but not done.

http://www.explorerforum.com/forums/showthread.php?t=92848&highlight=press+bearing

 

[Dan Whitaker]

Update

I know it's been about three months since I posted this but I finally solved the problem.

dogfriend, I should have listened to you. It was the CV joint on the front drive shaft.

I'm just glad that I finally have my Mounty drivable again.

I also want to thank Mounaineergree for the awsome deal on a used front drive shaft