04 Explorer makes a "clunk" noise and binds

[DSM1290]

When backing up and turning hard one way or the other, the explorer clunkes and seems to get on a bind. I replaced the front dr. side axle and it still does it. I got it off the ground and when you spin the wheels the front diff appears jump and it makes the clunk noise. So do the bushings that hold the front diff. go bad or is it something inside or what? Thanks for any help.

[Guest Removed]

sounds like a tooth broke off the ring or pinion. pull it apart and inspect

[Guest tbutera2112]

mustang clunked and bound up when i broke the teeth off my spider gears...maybe you will get lucky and thats all it is instead of ring and pinion

[DSM1290]

But wouldn't it do it all the time then? B/c right now it's only makes the noise and binds when backing up and turning sharply.

[rl]

There is a TSB for those, the differentials make noise (LSD) the fix is new clutch packs. I limped my mom's by with extra friction modifier, a year later its getting bad again so its going to come apart.

[Guest Removed]

There is a TSB for those, the differentials make noise (LSD) the fix is new clutch packs. I limped my mom's by with extra friction modifier, a year later its getting bad again so its going to come apart.

forgot about that

[DSM1290]

There is a TSB for those, the differentials make noise (LSD) the fix is new clutch packs. I limped my mom's by with extra friction modifier, a year later its getting bad again so its going to come apart.

 

What does that mean? Does Ford fix it then or what?

[Guest Removed]

Technical Service Bulletin

 

that means the posi in the front needs rebuilt.

 

heres one to check, check the tire height on all the tires

 

TSB 08-21-11

10/27/08

4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH

CONTROL TRAC - SHUDDER ON

ACCELERATION/DECELERATION OR BINDING ON

SLOW TURNS FORD:

1997-2008 Expedition, Explorer

2006-2008 F-150

2007-2008 Explorer Sport Trac

2008 F-150 LINCOLN:

1998-2008 Navigator

2003-2005 Aviator MERCURY:

2005 Mountaineer

2006-2008 Mountaineer ISSUE

Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to incorrect tire circumference or improper tire inflation pressures. ACTION

Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE

NOTE THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008 EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS. NOTE VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE REPLACED. NOTE REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE. NOTE ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX, SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE B-PILLAR OR EDGE OF THE DRIVER'S DOOR. NOTE ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT CAUSE FOR CONCERN. 1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the driver's door. 2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop Manual (WSM) diagnostics. 3. If the tire size is correct, ensure tire pressures are within specifications. 4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02. 5. Disconnect all wiring going to the transfer case and road test. 6. Is the shudder/binding present? a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM normal diagnostic for 4X4. b. If the shudder/binding is gone, proceed to Step 7. 7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected. http://alldatapro.com/alldata/PRO~V146863040~C38518~R0~OB0~P3R0H~N/0/101825161/102960169/102960255/102960257/34853741/34850750/42063452/139124574/140047547/140047548

8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4) tires and record the measurements. (Figure 1) http://alldatapro.com/alldata/PRO~V146863040~C38518~R0~OB0~P3R0H~N/0/101825161/102960169/102960255/102960257/34853741/34850750/42063452/139124574/140047547/140047549

9. Calculate the average of the circumference of the two (2) front tires and calculate the average of the circumference of the two (2) rear tires. (Figure 2) 10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or side to side, replace the smallest circumference tire(s) and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement. NOTE WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED WARRANTY COVERAGE. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

IMPORTANT : Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

 

heres the other one

TSB 06-4-4

03/06/06

LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING

SENSATION, OR VIBRATION DURING LOW SPEED

TURNING MANEUVERS FORD:

2002-2004 Mustang, Explorer

2003-2004 Expedition

2004 F-150 LINCOLN:

2003 Navigator MERCURY:

2002-2004 Mountaineer This article supersedes TSB 06-02-16 to update the Service Procedure.

ISSUE

Some 2003-2004 Expedition, 2003 Navigator, 2004 F-150 vehicles equipped with a 9.75" or 8.8" limited slip rear axle, and 2002-2004 Explorer 4dr, Mountaineer, and Mustang vehicles equipped with 8.8" limited slip rear axle may exhibit a chatter shudder, a binding sensation, or a vibration during low speed turns. On 4X4 vehicles, the sensation may appear to be originating from the front axle or the steering gear. ACTION

First verify the condition. On 4X4 trucks ensure that the vehicle is in 2WD, to isolate the rear axle. On all vehicles, turn the wheel fully right (or fully left) and then accelerate the vehicle. If the condition is verified to be in the rear axle, replace the limited slip clutch pack. SERVICE PROCEDURE

CAUTION INSTRUCT THE CUSTOMER NOT TO TOW WITH THE VEHICLE FOR 500 MILES (805 KM) AFTER THIS REPAIR, TO ALLOW THE AXLE TO BREAK-IN PROPERLY. Order and install the appropriate clutch pack, follow the instructions detailed in the Workshop Manual.

^ 6L1Z-4947-A (9.75" limited slip) ^ F5AZ-4947-BA (8.8" limited slip) NOTE INSTALLING A CLUTCH PACK INTO AN INDEPENDENT REAR SUSPENSION (IRS) AXLE IS DIFFERENT FROM INSTALLING A CLUTCH PACK INTO A SOLID-BEAM AXLE. BE SURE TO FOLLOW THE APPROPRIATE WORKSHOP MANUAL PROCEDURE. INSTALLATION TIPS

^ Be sure to install NEW circlips and halfshaft/wheel end nuts on IRS rear axle (not included in the service kit) ^ Soak the new clutch packs in Additive Friction Modifier (XL-3) for fifteen (15) minutes prior to installation ^ For IRS axles, the half shaft seals need to be replaced. Expedition and Explorer/Mountaineer applications should use seal kit part number SL1Z-4A109-A. Removal of the half shaft excluder seal 1L2Z-1N013 may be required, if equipped, to facilitate re-assembly ^ Refill axles with 4 oz. Additive Friction Modifier (XL-3) and the necessary amount of Rear Axle Lubricant (XY-75W140-QL), regardless of the axle lubricant system originally used in the axle. Fill to capacity recommended in the Workshop Manual NOTE AXLE FLUID REQUIREMENTS HAVE BEEN CHANGED. ALL VEHICLES BEING REPAIRED BY THIS TSB MUST HAVE REAR AXLE LUBE XY-75W140-QL INSTALLED, IN PLACE OF XY75W90-QFEHP. AS PART OF THIS REPAIR, CHECK AND REPLACE IF NECESSARY THE CURRENT XY-75W90-Q"FEHP" METAL TAG, WITH A NEW 75W140 TAG (F3TZ-4121-AA). ADDITIONALLY, REMOVE THE MULTI-COLORED LABEL WHICH IS LOCATED ON THE RIGHT SIDE, AXLE TUBE, OR BLOCK OUT ANY/ALL "FEHP" OR "75W90" REFERENCES ON THE LABEL.

http://alldatapro.com/alldata/PRO~V146863040~C38518~R0~OB0~P3R0H~N/0/101825161/102960169/102960255/102960257/34853741/34850750/42063452/121022605/118879169/118604058

[DSM1290]

Thanks, for the help it is for sure the front driveline that is making the noise and binding. I guess i will look into the tire thing but i'm pretty sure that is not it.

[DSM1290]

Tires are all new and the same size. Anyone else have an idea?

[Guest Removed]

the posi in the front..make sure you check all the bushing in the front end aswell.