1992 4wd clunk
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5th Wheeling
Joined: Sep 2011
Posts: 32
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1992 4wd clunk
i have a 1992 f150 4spd. and manual shift transfer case. when in 4 high driving down the road going straight i have a loud clunk and slight jumping of the truck. this happens about every 70-100 ft or so as im driving. it doesnt get better or worse when turning it does get a little worse when under heavy acceleration. clunk is only when transfer case engaged.
Senior User
Joined: Jan 2007
Posts: 191
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Are we talking about on dry paved roads, or dirt/gravel roads? Most people don't realize that since the ring and pinion are of different sizes in the two axles, the ratios are never "exactly" perfectly matched. Lets say you have a 3:55 rear axle ratio. The front gear set, being a small diameter may be actually 3:552. This means that tension will build up as you drive down the road. On an unstable road surface like snow, gravel, dirt, the tires can slip and relieve this tension buildup. On dry pavement, the only way to relieve this is for the tires to slip. This is why they tell you not to engage 4wheel drive on dry pavement. Good luck
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5th Wheeling
Joined: Sep 2011
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it is on icy roads, i dont run 4wd on dry pvmt. i feel it right under my feet. and i have manual locking hubs. i also ran it in 4low and had the clunk and jump just not as often. if i had to describe it i would say its like 4-5 teeth missing from a gear and jumping when it gets to that point. if it is the chain that is slipping is there a way to adjust it? thanks for your input.
Postmaster
Joined: Nov 2011
Posts: 3,533
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From: SW Florida
Which transfer case? How many miles on it? When my BW1356 transfer case started making noise it was cause it was jumping out of gear. The gears wouldn't completely engage. Tore it apart and found the oil pump retainer had worn thru the case (common problem), spun around and trashed the shift forks. The pump had also welded itself onto the output shaft. Good thing I was fixin to rebuild and install a manual shift case instead.
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joegeds
1987 - 1996 F150 & Larger F-Series Trucks
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Dec 3, 2015 11:45 AM
