I have a 2003 EB 4x4 with about 90,000 miles on it. It has the 2wd/a4wd/4x4 high/4x4 low selector on the dash. I have a rare but disturbing clunk when in 4wd high. I have never heared it when in A4wd, and I dont know about 4 low as I have never had the need for using it. I have also never heard it in 2wd. It sounds to me like it is coming from the front end but my hearing is all messed up so I have a hard time telling which direction its coming from. I can sometimes drive for 40 or 50 miles on snowy roads and never have it happen and then have it 3 times in a mile, then not again for months.
If I heard this sound in my 72 factory high boy my first though would be a hub not fully engaging and popping out, but dont know on this thing.
When I do hear it is usually when I'm driving on marginal 4x4 roads, such as when the ice starts melting and you are driving on bare pavement for a stretch between icy areas. I most recently noticed it yesterday when I was driving on the beach in fairly damp sand, so the traction was good. When I was driving in the drier looser sand I never heard it.
The tires are all exactly the same with the same mileage on all of them. It is time for a rotation as the rears do show a tiny bit more wear than the fronts but it is barely noticeable.
I have a 2003 EB 4x4 with about 90,000 miles on it. It has the 2wd/a4wd/4x4 high/4x4 low selector on the dash. I have a rare but disturbing clunk when in 4wd high. I have never heared it when in A4wd, and I dont know about 4 low as I have never had the need for using it. I have also never heard it in 2wd. It sounds to me like it is coming from the front end.....
Sounds to me like a 'normal' noise, especially as you describe it. With your comment about never having to use 4-low, I doubt that you've abused your front end to the point where you might have a bad gear or something else worn out.
Every 4x4 I've ever owned has "clunked" at one time or another (even my brand new Expy EL). If it were me, I would just keep an eye on it for any changes and not worry unless it gets worse.
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Mike
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'07 Expedition EL 4x4 (its really more of a 4x3... see the gallery ) Eddie Bauer, Tow Pkg
'08 F350 Crew LB (J3), 4x4, 6.4L, Camper Pkg
2007 Laredo 315RL 5'er, 35', 11.5k, Onan 4k
I guess maybe I understated the severity. It is not just a noise. It shakes the entire vehicle. It is enough that my non-mechanical wife and 5 year old daughter ask "what was that".
Anyone else have something like this happen? Like I said--it is very rare, but very disturbing when you have 150 miles of ice and snow ahead and behind you to think that it might blow at any time.
Non-Mechanical wife? As opposed to Mechanical Wife? The type you build yourself?
I would never drive in 4wd on roads that did not absolutely deserve it, only A4WD at most. It will cause binding, cause additional stress on your front and rear diffs, as well as center diff, and damage your drive-train.
Even though you have the same tires, with the same miles, etc, they're not going to be the exact same outer diameter, and since 4wd is forcing all wheels to spin at exactly the same speed, anything other would cause binding, and every once in a while, if the drive train doesn't get the opportunity to catch up, it'll "skip" a bit, which is what you're noticing. If it hits some gravel, or a place it can slip, it'll do it, and it won't clunk, and that's probably why you don't notice. But areas where there is nothing in the area for it to skip on, usually in the same small stretch, is why you'll hear it 3 times real quick.
Just searching through some old threads trying to find some info before I ask..
Mine 2000 EB makes a pretty harsh clunk as well when the A4WD engages in the snow/ice.
I climbed under today to check some other things and noticed that there is quite a bit of play in the front drive axle (between front differential and transfer case). I can turn it back and forth about an inch or so before it stops. Is this normal?
I can turn it back and forth about an inch or so before it stops. Is this normal?
The front axle, just one tire, or the drive shaft?
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Turn the key to on, then switch into 4WDH and see if there is any difference, then do the same in 4WDL. This is necessary to try and narrow down where the play is coming from. The 1" is a bit excessive.
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) Eddie Bauer, Tow Pkg 
