Have you verified the front hubs are not "stuck on stupid"? I've had hubs unlocked, with one or the other still grabbing the front axle. Grab the U-joint behind each front wheel and give it a spin. Verify the front driveline spins free from the transfer case. One item not freewheeling is an issue.

As for the rear driveline, I took mine in to a driveline shop for overhaul - that's where he found all the nasty stuff I listed on the driveline. They do a spin-balance on the driveline, which is far more exotic than a tire spin-balance.

 

I had some sort of rubber balancer on the rear shaft that had deteriorated and created a vibration that was clearly seen on a driveline shops balancer machine. They just made me a new rear shaft and rebalanced and problem solved. They also replaced u-joints with new Dana/Spicer parts since they had it down and were going to rebalance. Good for another 10+ years!

Good luck...

 

Good input, I appreciate it. I guess I will see if the drive line is balanced and bring it in to someone. I hope the part isn't defective, but who knows. My transfer case is all original. So it's quite possible that it may be worn out. I'm not sure who I can find around here to overhaul one. I kinda live in back woods Missouri. I will start with the little things and work my way up. Thanks brother.

 

Yes sir, I verified the front hubs are not locked or stuck. The front drive line spins freely and so do the u-joints behind each wheel. I will have to look for a shop that can do a spin balance on the drive shaft.

 

What rubber balancer are you mentioning? The only rubber piece I know, is around the carrier bearing and it does deteriorate over time. But that was just replaced with the new carrier bearing. The u-joints I'm replacing on the rear drive shaft this weekend. I'm looking for a shop that can balance it for me, without having to go to the stealership.

 

You are welcome, as always. If you have owned the truck from day one, you know how it has been treated all its life. If not, some things need to be investigated. When I think of all the times I was grinding away in low-range out in the sticks, I am just really thankful that mine gave up the ghost on the blacktop, ten miles from home. I had no clue it was going, it just went ! So it's worth looking at sooner or later. A good trans guy can rebuild it right, and it doesn't cost much. But I would look into the driveshaft first. I suspect you will have some luck there. Others on this site have tons more knowledge than I, so hopefully the real skilled gearheads will get with you, and give your Mystery Machine an attitude adjustment.

 

I forgot to mention, I believe I got the splines lined up correctly. I marked everything before taking it off and put it all back on the same way. I wish Ford had the extra wide notch on that spline. Chevy and Dodge have the extra wide notch on their splines so it only goes back on one way. Not sure why Ford didn't opt to do that.

 

Thanks BigRed. I know what you mean. I've owned the truck 9 out of it's 16 years. And I have done a lot to it since I've had it. Like my wife mentioned, I'm changing out everything that has been on it since day one. Once it's done, in theory it should last another 10 years or so.
I know what you mean, that would suck having it go out on you. I'm actually having a BTS trans installed in April. I might just ask them to look at the T case while they are doing the tranny. Like you said maybe I can get the drive shaft figured out and maybe that will squash this problem.

 

I hope you do. Most good trans guys will take a look at the T-case if the trans is coming out. A quick look will tell them the condition it's in. Besides, it needs new front and rear seals anyway, so he is already there. Also, have him polish up that flex plate and look for cracks. That can be a common weak point with these rigs. Saved me a headache down the road. Also a good time to r/r the rear main, if need be. I like to do things once, if I get a choice !

 

Dealerships are not equipped to do this, they send them out to driveline shops - when they don't insist on buying a new Ford driveline assembly.

 

So, I'm getting dirty today replacing the u-joints on the rear drive shaft. But I'm looking around at other things on the truck. So upon looking at the front end, I was checking the front u-joints which is on my list to replace as well. I noticed that where the stub shaft coming from the wheel assembly going into the yoke coming out of the axle is pretty loose. I mean, the yoke coming out of the front axle moves up and down about 1/4" I'd say. Is there supposed to be up and down movement on that part? And, is there a bearing race or is it just a seal on that end of the axle? I'm starting to wonder if the metal clunking sound that I have been hearing for a very very long time is coming from that.
The metal clunking sound I speak of, I have posted on other threads before. I was thinking that it was coming from the steering gear box because I have up and down movement on it as well, and I know that is not supposed to do that. But now I'm wondering if this yoke coming out of the axle has been clunking while I drive. It only makes that noise when I hit a bump or un-even surface on the road, or coming into my driveway which has a lip on it. So, maybe that piece is clanking around in there when these things happen.
Need some input ans answers to my 2 questions please. Thanks fellas.

 

The outer part of that front axle shaft Your feeling slack is supported by a needle bearing in the spindle tube, [thats my terminology] & also supported some by the locking hub,as far as slack,let Me go check mine.

 

My truck has about 1/8 movement prying between the yoke & balljoint,now I don't think that's a full 1/8 because the movement is rocking the shaft at a angle,the other side passenger was between 1/8 & 3/16 & is pretty quiet in 4x4 at highway speeds.

 

Ok, so since you have movement as well, does that mean this is normal? It just doesn't seem right to me. You can hear that metal to metal sound. I figured things should be tighter and smoother sounding than that.

 

So, what should have been an easy hour or so turned into an all day afair. Thanks to a buddy of mine with a bearing press, that's how I got my u-joints out of the rear axle. What a pain in the pooper that was. Needless to say I'm beat, and I will re-install this driveline tomorrow. We did find 2 end caps on the old u-joints that were toast. The needle bearings inside of them were disintegrated. I'm not looking forward to doing the other ones lol.