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Metal on Metal noise + clunk


xxxkudaxxx

New Member
Joined
Apr 16, 2008
Messages
2
Transmission
Automatic
2000 4.0 Ranger auto locking hub 4X4. Wife was driving it the other day and a grinding noise started up, parked it and came and got me. I could put the truck in gear, pull it forward and could feel a strange grinding noise that would peak with a "clunk" that you could feel not just hear. While driving it home I really thought that a rotor had broken and that the clunk that could be felt was the rotor grabbing a pad on the way around, this sound and clunk all kept time with the revolution of the wheels.

Had a buddy who used to be a cert. mechanic come over to help out, he looked up under while the vehicle slowly rolled. He said that he could hear the grinding and could tell that the clunk sound was on it's way because where the front drive shaft met the front diff, it would kind of bind up and gave him a visual indication.

This problem happened when in 2w or 4w, when trans was engaged or in neutral rolling. We dropped the front drive shaft and problem is gone. No visual cracks or damage to the shaft itself, got the u joint out of the front, it appears to have been fine, but gonna replace it now. This made me think that maybe something was up in the transfer case, with the front drive shaft out, I could put it in 4 WD which should cause the yoke on the transfer case to spin which it did, but there seemed to be no problems

If there was something wrong in the front diff or trans case, shouldn't the grinding noise, the clunks and the feel still be there? I've got the yoke on the front diff spinning when the front wheels roll, the yoke on the trans case spinning when in 4WD, add the front drive shaft and I've got problems, drop the drive shaft and I'm good to go. Buddy says that he's heard of drive shafts looking fine but being bad.

I'm lost, any help would be most appreciated.
 
the clunk ... there is a TSB from ford about a dry driveline slip joint problem. Re grease the driveline slip joint. (make sure you index it before disassembly.

the grinding ... no clue
 
Update

Knowing that it had to do something with the front drive shaft, I went ahead and replaced the u joint between the drive shaft and the front diff, problem seems to be fixed.

I've never heard of a u joint making that amount of noise and not have some type of indication that you could see, but boy am I glad.

Thanks for the replies
 

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