Driveshaft noise

[lucky14]

I have a 2001 Ranger 4dr supercab, 3.0L V6 with a manual and Aluminum DS

I have a loose either slag, weld, or other debris in the DS simlar to:


16650 2001-2003 RANGER SUPER CAB 4X4 - DRIVESHAFT RATTLE NOISE
SOME 2001-2003 4X4 SUPER CAB RANGER (EXCLUDING FX4) MAY EXHIBIT A RATTLE NOISE FROM THE DRIVESHAFT, WHILE DRIVING. THIS RATTLE NOISE MAY BE DUE TO A PLASTIC CAP THAT HAS BEEN DISLODGED AND IS ROLLING INSIDE THE DRIVESHAFT. TO SERVICE, REPLACE WITH A NEW REVISED DRIVESHAFT PART NUMBER 3L5Z-4602-LA.
EFFECTIVE DATE: 02/27/2003


Has anyone tried to get a DS out of Ford out of Warranty or had sucess in getting the cap out without cutting the DS open? In example, is there a opening in the slip yoke end that it could be fished out.

Im lazy and haven't pulled the DS just confirmed the rattle is interior to the DS

 

[AllanD]

If you dismount the driveshaft and seperate the front slip yoke from the shaft
and look inside you will see a plastic cap that is supposed to keep the grease from migrating down the shaft away from the slip joint.

It's vaguely dome shaped and ~3.5" in diameter.

And I can tell you getting it back into position is simply impossible, nor would it stay there anyway...

Almost as difficult is getting it out of the the inside of the shaft, difficult, not impossible.

What I'm doing with one of those shafts with the loose cap is I'm going
to fill it with great stuff foam.

But I'm going to use a four foot lenght of vinyl tube so I'm sure it gets
to the bottom before expanding.
after it cures I'll top it with a layer of somewhat fluid epoxy

I figure that if the aluminum shaft is quiet as the factory made them one
filled with foam will be even quieter, not to mention far more rigid.

AD

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[4x4junkie]

I think that would throw it way out of balance, no?

 

[AllanD]

even filled with foam will only add 10oz to the entire weight of the shaft.

I've got one shaft that still has it's loose cap inside, I can get it into position
And there is a vent cap in the foirging at the back end of the shaft.

I'm now thinking that coaxing the cap into place then fixing it there with
a plug of foam would make sure it stayed put.

worst case having the shaft balanced shouldn't be impossible
provided the welder who applies the balance weights can work fast...
(so as not to melt the foam inside the shaft)

AD

 

[Downey]

or catch the foam on fire

 

[lucky14]

Yea wow... that sounds like a VERY bad idea. Filling the DS with foam.. you can not ensure the foam will expand equally WITHOUT VOIDS nor could you ensure that the foam would expand longitudaly down the shaft to the end of the fixed yoke on the end of the DS. Either contingency you would not be able to fully balence the shaft.

My idea was to attempt to remove the cap. If the cap is plastic you shold be able to break it in half and remove the smaller pieces.

 

[rboyer]

Simply breaking and removing the cap would be all fine and dandy but then what would be there to serve it's original purpose once it's gone?

 

[AllanD]

or catch the foam on fire

Obviously not a boy scout (understanding a fire triangle)
And not understanding common welding techniques for aluminum.

MY aluminum welding guy also works on titanium and welds them
under water.

Or use a strap on balance weight

As for the foam not expanding evenly?

That would be weird...

AD

 

[lucky14]

So really my plastic cap or whatever it is so freaking annoying.. I think that I might give it a try to and pulling the DS out this Thursday during open shop night.

Anyone had any sucess getting it breaking it apart or getting it out?

 

[lucky14]

I Yanked my DS out... the cap was loose.... I have understood that ford has used the same crappy design with this frost plug in it's driveshafts since the 1970s...

I was told by a fellow technician that back in the day in the 1970's that the fix WAS to fill it with foam.... wow what a stupid idea...

I propped the DS up on some rubber blocks... tilted the DS down so the cap rolled down, grabbed it with forecipes, then used my air saw cut in thirds then pulled the pieces out... wa-la