Hear and feel a knocking in the drivetrain that’s consistent with driveline rotation? it could be a broken gear tooth in the rear end.
It is more common to have a damaged tooth in the spider gears (side gears) than on the ring and pinion, although, anything is possible. If you do start getting a knocking sound in the rear end, you need to check it right away before you do more damage.
In the photo below is an example of a broken tooth in the spider gears:
If you haven’t damaged the ring or pinion gear, then this can be fixed fairly reasonably.
Your choices are:
1) Buy a new set of pinion gears and install them
2) Upgrade to a locker that replaces the side gears such as a Lock-Right.
3) Weld up the side gears to form a “Lincoln Locker” or spool type of setup.
Welding the gears should only be done by an experienced welder with experience welding up spider gears.
About The Author
Jim Oaks is the founder of The Ranger Station, one of the longest-running Ford Ranger enthusiast communities on the web. He has spent over three decades owning, modifying, repairing, and driving Ford Rangers on the street, trail, and cross-country routes.
Since launching TheRangerStation.com in 1999, Jim has documented thousands of real-world Ranger builds, technical repairs, drivetrain swaps, suspension modifications, and off-road tests contributed by owners worldwide. His work has been referenced by enthusiasts, mechanics, and off-road builders looking for practical, experience-based information rather than theoretical advice.
Jim’s hands-on experience includes long-distance overland travel, trail use, drivetrain and axle upgrades, suspension tuning, and platform comparisons across multiple Ranger generations. The content published on The Ranger Station is grounded in first-hand experience and community-verified data, not marketing claims or generic specifications.