Would appreciate some help with diagnosing a problem. I have 1992 4X4, Ford manual hubs, Dana 44 with 3:55's and NP 13-56 transfer case. The hubs lock easily and the 4X4 still works in both hi and low range. But it makes a "clunking" noise when pulling or under load. It is doing it in both hi and low range. It seems to do it only on rough surfaces that cause the tire to move up and down, not necessarily bounce, just move up and down. It sounds to me like it is coming from the drivers front side. I'm guessing that something is going but don't know enough to say if it's in the hub assembly or is one of the axle CV joints or whatever. There don't appear to be any similar noises at all from the area while in 2WD. Any help would be great. Thanks in advance.

1992 F150 Supercab SB 4x4 302 AOD 3.55 31x10.5 All Terrain on Ford 15x8 Ralleys

 

Inspect the U joints on the front driveshaft & both front axles . Since its only making the noise in 4wd Id concentrate on the front driveline components . Does the noise get worse , stay the same when you make a turn ?

 

Take a close look at your motor mounts and the Radius arm bushings. Check the shocks/mounts also. I have heard of loose rivet problems on Ford frame/front ends.
-Chris

 

I had a clunk in the front passenger side that turned out to be a loose bolt on the sway bar. Once it was tightened, the clunk was gone.

 

My 86 did the same thing and I couldn't find it everything looked fine as it got worse it was easy to find and it was a cv joint usually the outer one goes first but if you change one do them both and save yourself the problem of taking the axle out again. John (FATFORTY)

 

 

Thanks for the comments. I'll get it sorted out and post the results back.

1992 F150 Supercab SB 4x4 302 AOD 3.55 31x10.5 All Terrain on Ford 15x8 Ralleys