Rear end "Clunk"

[Ranger Mike]

I have read a lot of posts related to rear end clunking, but none seem to be what is happening to my 89 ranger. I bought the truck to use only on occasion to haul brush or for a trip to Lowe's, but I like driving it so it is used just about everyday. As soon as I drove it home after buying it, I found the engine leaking oil onto the exhaust. I drove it like this for about a year. I recently (last week) repalced both valve cover gaskets. I also wanted to repalce a leaking rear end cover. When I removed the cover, I found out it was plastic and had a big crack in it. Over the past two weeks or so, I had noticed the inside rear tire spinning like crazy when making a tight turn to either side. It would also make a loud clunk and seem to free up on occasion and the spinning would stop. I thought that since the rear was leaking, it was just low on fluid. Today, I replaced the cover and filled the rear with fresh fluid. I just took it around the neighborhood and it is clunking just the same as it was before, maybe worse. What could the problem be? Does the rear need rebuilt? I did find some metal shavings sticking to the fill plug and in the bottom of the hosuing when I changed the cover. Any help is appreciated...

 

[4x4junkie]

Did the spider gears look OK? (no broken/chipped teeth)?
Any gear whine noise?
Is it a limited slip or standard differential?

 

[Ranger Mike]

It is a standard rear. I didn't notice any teeth missing on the spider gears when I had it open. I did just add a little fluid a few minutes ago to be sure it had enough in it and I found lots of shavings on the plug again. I had cleaned all the shavings I could find out of the hosuing previously. I don't have a good feeling here.

 

[Ranger Mike]

I forgot to mention. No gear whine.

 

[martin]

Is it in four wheel drive?

 

[Ranger Mike]

yes, 4 wheel drive.

 

[Ranger Mike]

It is 4 wheel drive.

 

[martin]

Yes, but is it in four wheel drive when it is doing this.

 

[Ranger Mike]

I have not had it in 4 wheel drive to see if it still does it. I suspect it will. When it makes the noise it feels like there is a cement block rolling around in the bed f the truck and banging off of the sides.

 

[4x4junkie]

It sounds to me a deeper inspection is needed inside the diff.

A bad spider gear could cause symptoms similar to what you describe (not all that unusual on the 7.5").

 

[martin]

Sounds to me like it's in four wheel drive.

 

[maroon ranger]

Just a quick question...why does it do that in 4 wheel drive? Is it cause of the spiders engaging and disengaging or is it to do anything with the u-joints or is it cause of the transfer case or a combination of any of these? I have always wondered about that.

 

[Mac]

If you're finding shaving in there, it's not going to get better. Prepare for some work. I always liked rear ends with a magnetic drain plug in them.
Dave

 

[Ranger Mike]

I will pull the cover again and take a closer look at the gears. Thanks to all.

 

[Ranger Mike]

I pulled the cover again and spun he gears. Spider gears are indeed worn. One is missing tooth all together. I cannot find it in there though. What now? Is it better to just put in an entire new rear from a junkyard or try and rebuild this one? I want to keep this as cheap as possible. Thoughts?