2002 FX-4 front driveshaft

[Big Jim M]

Please! What is the doohicky on the front driveshaft next to the transfercase? It appears to have the driveshaft coming out of it at an angle and not straight away. Is it some kind of fancy U-joint?
Is it replaceable?
Does the fluid run out of the transfercase when it is pulled?
I can LIFT the driveshaft a bit and it makes a CLUNKING sound inside the doohicky when I lift. Is this unusual?
All information is welcome.
The reason I ask is I still have a small HARMONIC vibration at steady throttle 60mph.
Oh yeah 75K on the vehicle.
Big JIm

 

[4x4RangerGuy]

Are asking what kind of joint is used at the front output of the transfer case?

It's called a repezza joint. It's basically just a CV joint. The "cup" (housing for the joint) bolts to the front output of the transfer case, and the end of the driveshaft that connects to the transfer case has the cage and balls integral to the driveshaft. The cage and balls slide into the housing and the integral cover on the driveshaft covers the housing with 6 bolts IIRC. It's quite similar to a CV shaft.

This style of joint provides less vibration than a standard UJoint. However, it sounds like you may need to regrease the joint and clean up the housing and cage since it shouldn't move TOO much and definitely not make a clunking sound.

Unbolt the driveshaft from the front differential (standard ujoint straps) and then unbolt the 6 bolts holding the cover on at the tcase end of the front driveshaft. To remove the bolt heads you'll need an Allen wrench IIRC. Then, carefully pry the cover off of the housing, and carefully remove the driveshaft from the housing (be careful as the balls will most likely fall out of the cage when you do this). Clean it up nice and grease up the cage and balls. Put some grease into the housing on the tcase as well. Reassembly is the opposite.

 

[Big Jim M]

Are asking what kind of joint is used at the front output of the transfer case?

It's called a repezza joint. It's basically just a CV joint. The "cup" (housing for the joint) bolts to the front output of the transfer case, and the end of the driveshaft that connects to the transfer case has the cage and balls integral to the driveshaft. The cage and balls slide into the housing and the integral cover on the driveshaft covers the housing with 6 bolts IIRC. It's quite similar to a CV shaft.

This style of joint provides less vibration than a standard UJoint. However, it sounds like you may need to regrease the joint and clean up the housing and cage since it shouldn't move TOO much and definitely not make a clunking sound.

Unbolt the driveshaft from the front differential (standard ujoint straps) and then unbolt the 6 bolts holding the cover on at the tcase end of the front driveshaft. To remove the bolt heads you'll need an Allen wrench IIRC. Then, carefully pry the cover off of the housing, and carefully remove the driveshaft from the housing (be careful as the balls will most likely fall out of the cage when you do this). Clean it up nice and grease up the cage and balls. Put some grease into the housing on the tcase as well. Reassembly is the opposite.

Do the balls fall out when under the vehicle or when on the bench? Also does the transfercase lose oil?
And many thanks for the great explanation. REPAZZA JOINT That is the first time I have seen that name in print. I might even google it just for grins.
Big JIm

 

[Jspafford]

Do the balls fall out when under the vehicle or when on the bench? Also does the transfercase lose oil?
And many thanks for the great explanation. REPAZZA JOINT That is the first time I have seen that name in print. I might even google it just for grins.
Big JIm

The T-case should still be sealed. Your only taking half the output off, part of it will still be bolted to the case keeping it from leaking.

I think it's spelled repezza.

 

[Big Jim M]

Thanks tomorrow is the day!
Big JIm

 

[Jspafford]

Thanks tomorrow is the day!
Big JIm

Well did it go well?

 

[Big Jim M]

Oh yeah!

Well did it go well?

I had the rear driveshaft balanced. New u-joint installed and the repazza regreased with the new ford grease..(I think he used that anyway).
The noise didn't go away.
So I pulled the front driveshaft and regreased the flex joint at the transfercase. I also installed a NEW U-joint on that driveshaft.
The results of the driveshaft efforts did NOT stop the harmonic noise... However The vehicle was having a problem with the rear joints causing axel wrap...which has gone away.
I have come to believe the harmonic noise is coming from the variable intake. I have read up on the variable intake and have found that it is SUPPOSED to make a noise at certain rpm's.. I guess I will simply have to drive faster so the rpm will not be at the sweetspot any longer.
Big Jim