2002 RWD diff clunking

[dachenba]

Hello Forum
I have a RWD 2002 ranger 3.0. which has a clunking noise that appears to be coming from the rear diff. It is a high mileage vehicle, 186000. The engine was replaced but it has the original 5 speed manual trans. The drive shaft seems to be ok. It was removed and the universal joints appear good. I did "dig" into the diff multiple times to fix this issue.
- spider gears were replaced (and gear shaft)
- all bearings were replaced, wheel, carrier and pinion. (the pinion shim was reused)
- pinion preload was set to approximately 20 in lbs.
- carrier shims were adjusted to obtain 0.007-0.008 backlash
the free rotation of the diff flange with the rear wheels on the ground appears to be excessive. (approximately 1/2 in of rotation). I'm thinking the excessive rotation is causing the
clunking noise. With the Diff cover off, there appears to be very little backlash in the ring and pinion. Most of the free rotational appears to be coming from the spider gears and spider gear to axle.
Does the carrier need to be replaced? Do the axles need to be replaced?
This clunking can be reduced by always easing the clutch out, but this drives me crazy.
Any suggestions?
THANKS

 

[franklin2]

So it only clunks when applying power, or taking power away? Cruising down the road there is no clunk?

 

[franklin2]

No matter if you have the 7.5 or the 8.8, both axles use wheel bearings that ride directly on the axle shaft. So they are a item than may need to be replaced from wear. In other words, it's not earth shattering occurrence to have to replace the axles.

I see rockauto has them for little over $100. But there are several choices, you might end up pulling them to see what you need to order.

 

[dachenba]

Cruising down the road there is no clunk.
backing off and on the throttle are low RPM seems to cause the issue and also dumping the clutch

 

[dachenba]

So it only clunks when applying power, or taking power away? Cruising down the road there is no clunk?

Cruising down the road there is no clunk.
backing off and on the throttle are low RPM seems to cause the issue and also dumping the clutch

 

[JohnnyO]

Back then there was a TSB about replacing the driveshaft because the slip yoke was manufactured a little too long and there wasn't any room for slack but if that was the problem I think you would have noticed before now.
I had a 99 Ranger and an 02, both purchased new, and had to have the driveshaft replaced on warranty on both due to clunking and banging.
The OE driveshaft was steel and the replacement was aluminum. If you can find the correct aluminum version in a junkyard for cheap it might be worth a shot.

 

[dachenba]

Back then there was a TSB about replacing the driveshaft because the slip yoke was manufactured a little too long and there wasn't any room for slack but if that was the problem I think you would have noticed before now.
I had a 99 Ranger and an 02, both purchased new, and had to have the driveshaft replaced on warranty on both due to clunking and banging.
The OE driveshaft was steel and the replacement was aluminum. If you can find the correct aluminum version in a junkyard for cheap it might be worth a shot.

Thanks for the reply, my rwd 2002 does not have a slip yoke however.

 

[Jazzer]

No slip yoke at the transmission /driveshaft connection?

 

[sgtsandman]

Thanks for the reply, my rwd 2002 does not have a slip yoke however.

RWD driveshafts on Rangers often have the slip yoke where it slides into the rear of the transmission instead of in the middle of the driveshaft. So, it's there, just not in the usual spot some may be used to.

 

[dachenba]

No slip yoke at the transmission /driveshaft connection?

Drive shaft is direct connect from tail shaft of the trans to diff flange. (Utilizing two universal joints obviously

 

[dachenba]

Drive shaft is direct connect from tail shaft of the trans to diff flange. (Utilizing two universal joints obviously

The drive shaft can slide in and out of the trans tail shaft.

 

[Jazzer]

The (inside) splined male portion of the yoke that holds the ujoint and slides into the trans tailpiece should be your slip joint.