Noises from tranny or transfer case

[wollimann]

hy guys,

I don’t believe in miracles, but i hope i will find some help in this awesome instance.
Our loyal companion since 1997 (made in 96) 4X4 V6 SOHC, make some noises coming from transmission (5R55E) or transfer case.
Condition:
- last year he became a overhauled transmission, everything was fine
- rear cardan shaft were changed, joints are ok
- front cardan joints (both) were changed
- rear diff were overhauled
- front diff has a little tolerance
- oil MerconV in best condition
- transfer case chains changed
Description:
- Driving in normal condition D, while the tranny shifts down to idle, there comes a noise like “clonk” and a little hit goes through the Ex.
- this behavior comes in cold and warm oil conditions (warm oil -> louder)
- the noise comes only while driving slowly, like braking in front of traffic light
- driving without the front cardan, noises are still present
- driving in position 2 the noise doesn’t appear
So what can I additionally do to localize/isolate the fault?
Reading in this and German forum doesn’t find any references.
Our German work shop of confidence (no ford dealer but specialized on EX) wrap himself in
silence.

greetz from Europe

Wolfgang

 

[96eb96]

It is possible the rear splined slip joint needs lubrication? It could bind up under torque and not release properly. It is inside a rubber boot on the rear driveshaft. It requires a special grease called motorcraft xg-8. Look up that product and see the symptoms. It is a PTFE Lubricant.

 

[wollimann]

Thanks very much for this hint, i will grease up the slip joint. Hope Ford Germany knows the xg-8!

Wolfgang

 

[wollimann]

Slip joint is greased up but clonking is going on. Think the Ex should spend some time in hospital

so long

Wolfgang

 

[wollimann]

While i still have this clunking noise, looking for a transfer case Borg Warner 4405 with the number F77A-7A195-GA.
If anyone has some information where i can catch one please tell me. It should be ok and have the VSS, odometer connection and shiftmotor installed.

I found a link
http://poconos.craigslist.org/pts/3350675677.html
but the seller doesn't answer on mails.
Maybe the TC is still sold or he thought what a stupid guy.

I am confident to find a good one, but it seemed to be not so easy.

Wolfgang

 

[wollimann]

Found one bw4405 but the case half are worn out (bearing housing's).

Found the "Transfer Case Rebuild Diary" -> not for warm shower takers.

Now try to fix the casehalfs.

so long

Wolfgang