New '03 Explorer AWD - some issues

[Ghostman]

Just bought a 2003 Ford Explorer AWD model(or 4wd maybe, but only has option for auto or lock in 4wd hi) for my wife. It's green and had 101000 miles on it. Exterior was extremely clean IMO, inside is pretty darn good shape too besides the radio faceplate comes off, carpets a little dirty, and drivers seat is a little soft. Other than that its great.

I only paid $1500 for it knowing it had a bad front right wheel bearing. The guy I bought it from wasn't much of a mechanic or had any knowledge of the car. My wife cleaned it thoroughly and here is a list of everything I replaced myself. I am a very good mechanic and do vehicle maintenance etc all the time, although it's mostly on diesels and big trucks:

-Front wheel bearings with new ABS sensors
-Front discs, calipers, pads, caliper line and bolt
-New brake fluid and bleed
-New upper and lower a-arms with all new joints ofcourse
-New CV shafts
-New outer tie rods
-Two new tires, other two are pretty good shape- near new
-Got alignment after all installed
-Changed oil
-New valve cover gaskets (inspected timing chain etc. all good)
-New intake manifold gaskets(had to while doing valve covers)
-New spark plugs
-New Gates, tensioner, idler, belt


Now what I know is still broken and needs to be done:
-Flush and replace coolant
-upper/lower t-stat housing is cracked I believe, needs new t-stat
-change transmission fluid and filter, and t-case fluid
-change diff fluids

Now my problem is this:
When driving at any speed I can feel in the driver side floor board and grinding/humming sound and hear it as well but only while the steering wheel is turned left, even just ever so slightly left. Turning right makes it go away. It even sounds like its in the rear of the car, makes a person would think is a lot of tire road noise. I have rotated the tires and no difference. I've read lots of threads and no one ever came to a conclusion as what the problem actually was. I have another unit bearing I am going to swap with the front left just to eleminate that possibility. It slightly sounds like bad bearing. It will even thud more like something is loose and knocking sound. I have inspected everything in the front and everything is good.

Any ideas what too look at next?

Also any feedback on what these vehicles tend to do or need maintenance on is appreciated. I feel it could be a good reliable vehicle, at least I hope for another year or so till we buy her a new vehicle.

Sorry for longwinded post and thanks in advance.

 

[pet575]

If you can rule out the wheel bearing you might think about pulling the axle out of there to see if that quiets it down. I've had CVs click, hum, vibrate, etc. when they've gone bad.

 

[Ghostman]

If you can rule out the wheel bearing you might think about pulling the axle out of there to see if that quiets it down. I've had CVs click, hum, vibrate, etc. when they've gone bad.

Swapped wheel bearing and no improvement. I'm going to try to take a look at the front diff next.

CVs are new, but I guess one of those could be bad out of the box too.

 

[scottfab]

Had this issue and fought it for years and you simply will not believe what it was. Once my son owned the Explorer and put new tires on it the sound when away. Same deal, it use to quiet down when cornering and was coming from the left front. Did NOT go away when rotating tires.
The theory is that the tread pattern caused the issue.

 

[drdoom]

Mismatched tires I agree with Scott. The transfer case and it's related systems are very sensitive to tire circumference. It is usually the first item to check, and many many Explorers have had to have all four replaced. Proper (frequent) rotation intervals and pattern(s) are critical.

 

[roush9799]

X 2 on the tires. I replaced my rears on my mounty with the same brand tire that was on the fronts. Had a slight vibration and a lot of noise. Checked bearings and such, finally replace the front tires and all noises disappeared. Even my slow speed binding when I would turn in a parking lot lessened to where I don't worry about it now.