Ford - Explorer :: Distinct Grinding / Chunking Noise When Punched The Gas Hard At Any Speed In Any Gear


Sep 14, 2013

The history: I have a 98 ford explorer 156k miles. V6 automatic AWD w/ 4WD. I recently took it in for a rebuild on the transmission due to 3rd gear slippage. When I picked it up (after business hours) the dashboard lit up like a christmas tree with code lights about 4wd & OD. It drove fine and I needed the vehicle so I took it and called the mechanic the next day. He advised me if they did something wrong they would fix it but he would have to run the codes to know what was going on. He told me if it drove fine it was ok to take my time about coming in. Since it was an hour drive (and time off work) I waited till the following week. They ran the codes and determined that they had forgot to "plug my 4wd in" and it was throwing every code possible for that system. Lol...

The problem: During the week I drove it I noticed a distinct grinding / chunking noise when I punched the gas hard at any speed in any gear. It happens about 85% of the time and is sometimes light noise and sometimes very bad.

I knew previously that I had bad ball joints so I figured it was that issue making a grinding noise based on the truck rocking back when I gassed it hard.
After about 2 weeks of hearing the grinding occasionally, it gets to bothering me so I go get the ball joints fixed. New ball joints and it still grinds... Now Im really worried it the transmission so I go back to the transmission mechanic yesterday (another half day off work and hour drive) and he test drives it. Tells me it is the transfer case going bad. Also tells me it wasnt like that when I picked it up because they 'test drive' every car after the work is complete (but somehow didnt notice the flashing codes on this test drive).

The question:
Is it possible while rebuilding the transmission or installing it, that they damaged the transfer case?
Are these systems connected directly to one another?
Is it possible that my 4WD being unplugged for a week or so of driving could have caused an issue in the transfer case?
Is it possible that if the 4WD was 'unplugged' the AWD may have also been disengaged and as a result caused an issue in the transfer case?
Is it likely that its just normal wear on two closely related systems and I should just suck it up and get it fixed?

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I have an early 99 F250 4x4 7.3L..... 4R100....

Brief history, a while back on way home from work I let off of the accelerator and had a loud gear meshing like grinding noise, got back on the accelerator and went away, let off and back, so I quickly stopped and pulled over, went through the gears and reverse, everything seemed ok,??? went on my way, got home parked the truck and went about my evening. came out next day to leave and truck wouldn't move in reverse, forward but not reverse. long story short I was told that the snap ring internally probably came out, I have heard of this being a big issue with these, so I set up for it to be rebuilt, got it back and installed and still same issue, what the crap so I ended up having to pull it back out and amongst my own trouble shooting I found the simple issue and was the nylon riders on the 4hi/4low shifter fork were completely gone and allowing the planetary group to free float in and out of 4x4 neutral!!! NOW on to the issue at hand. so far only thing has been done is rebuilt and those fork riders replaced.

now I can move but 2-3 upshift under a load(more noticeable) has a delay going from 2nd to 3rd and under a load it hits hard. I talked to the guy that rebuilt it and he said that the rebuild kits don't always the right springs for the valve body and causes shift issues, so he talked me into the shift corrector kit which I researched and did see what he was saying, so had that done and still no better, still does it, however, it does shift into the gear softer but didn't fix the delay or the hitting hard when it did finally go into 3rd.

After being forced to drive it that way I have since determined that what it happening is it is coming out of 2nd with a second and half pause and then shifting into 3rd, the hard shift comes in to play because during the delay the torque convertor is locking up making it a direct drive like popping the clutch on a standard!!!

I just swapped out the sol pack and I heard from a youtube video that the bolt next to the 2-3 upshift valve on the valve body could be to tight and making a sticky valve, so I re-torqued all the bolts and nuts put all back together and test drive proved to be worse, I now have same issue in all upshifts. all hit hard now, I am at a loss and don't know where to go from here, I can only imaging the sol pack is causing this but I have yet put my org one back in to see... oh and I found two bolts on the accumulator stripped and found one non torqued bolt on the main valve body!!

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There are 2 noises, the first is the noise we hear, the second is one that i found when doing the noise reduction (loud meaty tires you cant hear the noise in the audio without reduction) I think that that was one of the hubs, or maybe the brakes, I am unsure, but it happens at different locations in the video.

Audio : [URL] ....

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Link " [URL] .....

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