2009 Ranger FX4 4x4 issues

[Rangerdano]

Hey guys,

I got a brand-new transfer case put in my 2009 fx4 last year and it was making a clunking noise every 10-20 seconds when driving it in 4x4hi after they installed it. It sounded like a gear slipping or something like that. It never jumped in and out of 4x4 just would make this clunking noise. I took it back to the mechanic and he thought maybe it was a faulty T-case so they sent that one back for warranty and installed another brand new one. And still it makes the clunking noise when driving in 4x4hi! He said he is not sure what is causing this clunking noise when driving in 4x4 and figured maybe it was because I have 33in tires on the truck and the tread wear was uneven causing the gears to slip. I'm 99% sure that is not the problem.

Anyone have any suggestions what may be causing this?

Thanks


Dan

 

[Haywire6000]

Same size tires on all four corners I assume? Also, I assume you are not testing this on blacktop?

 

[Rangerdano]

Yeah roger that. Same size and driven on snow and ice

 

[pjtoledo]

a couple thoughts,
first, gears cannot slip unless something is broken.

does the time interval between the clunks change with speed? 20 vs 40 mph?

there used to be an issue with the driveshaft splines binding and releasing instead of smoothly sliding. was most noticeable stopping and starting. good grease was the fix, at least its cheap and doing it won't hurt anything. its a long-shot of course.

possible the tires are slightly different sizes, maybe caused by different pressures, wear, and loads.
a quick test of that would be an isolated road or parking lot.
use 2wd for the test.
park the truck and chalk mark all the tires at exactly bottom center. drive forward perfectly straight about 100ft/10 revolutions of the wheels, stop with one wheel at exactly the bottom again, compare it with the others.

put it on jackstands, engage 4hi, hit the gas and apply brakes for load. maybe you could duplicate and isolate it that way.

pull the rear driveshaft, drive in 4hi. still there?
repeat with front driveshaft removed.

if none of this helps, throw expensive parts at it until frustrated. then sell truck packed full of new parts to me.


Perry

 

[pjtoledo]

back up a minute, why did you get the first transfer case replaced?
how is the truck used/driven?

 

[Rangerdano]

a couple thoughts,
first, gears cannot slip unless something is broken.

does the time interval between the clunks change with speed? 20 vs 40 mph?

there used to be an issue with the driveshaft splines binding and releasing instead of smoothly sliding. was most noticeable stopping and starting. good grease was the fix, at least its cheap and doing it won't hurt anything. its a long-shot of course.

possible the tires are slightly different sizes, maybe caused by different pressures, wear, and loads.
a quick test of that would be an isolated road or parking lot.
use 2wd for the test.
park the truck and chalk mark all the tires at exactly bottom center. drive forward perfectly straight about 100ft/10 revolutions of the wheels, stop with one wheel at exactly the bottom again, compare it with the others.

put it on jackstands, engage 4hi, hit the gas and apply brakes for load. maybe you could duplicate and isolate it that way.

pull the rear driveshaft, drive in 4hi. still there?
repeat with front driveshaft removed.

if none of this helps, throw expensive parts at it until frustrated. then sell truck packed full of new parts to me.


Perry

Thanks Perry I will give that a try to check the tire size. Even if they are off by a little bit do you think that could cause this? The clunks seem to be random, sometimes 20 seconds apart, sometimes 40? There is no distinguished pattern. It did seem if I was going up hill and giving it more gas there was always a clunk.

I bought the truck used, and after about 1 year of driving it, pulling into a parking lot I heard a loud pop and the T-case was cracked right down the middle and all the oil spilled out. Got it towed to Mr Transmission which is where I got a new one put it.

Thanks guys for the replys

Dan

Dan

 

[pjtoledo]

they will be off some, no 2 tires are exactly equal, different wear patterns, pavement irregularities etc. I would be mostly looking to see if one particular wheel was much farther off than the others. on ice or snow they should slip to relieve drivetrain bind. what happens if you do some tight circles in 4hi on ice? something will definitely have to slip then, should be the inside rear wheel.
have you tried 4 low yet?

do you have an auto-locker in the rear axle?

 

[Rangerdano]

Thanks for the response!

4 low is fine. Does not make the clunk. I don't think I have an auto locker in the rear axle.

 

[enjr44]

I don't think whatever caused the original t-case to crack has been fixed. There is something between the t-case and the front wheels causing it.

The clunking you have is the same old problem trying to break the two new t-case assemblies. Don't understand why it does it only in 4H though.

Does it "clunk" with the front drive shaft removed?? The t-case doesn't know if that shaft is in there or not. It just cranks the shaft and assumes.

 

[Rangerdano]

I have not tried to remove the front drive shaft yet. The old T case cracked when I was in two wheel drive.

Thanks

Dan