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I have a 93 F250 with stock IFS. My problem is it makes a clunking noise when driving in 4x4. I have checked for any noticeable problems like bearings and u-joints but see nothing wrong. I think the noise is coming from the front differential. Does anyone have experience with this issue before I tear it down on a witch hunt?
Siezed u joints and bearings from lack of use are the most common problems with these, unless it's obvious that sombody had recently serviced the front driveline I bet you will find more than one issue when you take it apart. Diff problems are no more or less common than with any other, the pumpkin detatches from the TTB arm once the drive axles are removed.
The 4x4 has been used weekly since I've owned it. Over 10 years. It's been making this noise for about a year and every time I use the 4x4 I expect a disaster. I'm finally getting around to fixing it.
Problem identified. Cv joint just in front of the transfer case has a bad center bushing. Rebuilding the whole front end now that I have it all apart. Needed done anyway.
Sounds like your truck (F-250?) was upgraded. They came with standard u joints on the front driveshaft originally but there was a tsb (I think that's what it was?) for updating to the double cardan joint at the transfer case to eliminate a driveline vibration. F-350 trucks had them stock, the 3/4 tons were borderline needing them it seems.
Nope the CV joint just 2 inches in front of the transfer case
Well OK... that is interesting, the thing is these trucks did not use CV joints in any part of the driveline from the factory. So maybe you have a custom front driveshaft. Can you post a picture?
I found the part number tag dated 1995 on the driveshaft. Interesting since the truck is a 93. I know the Dealership would have put it in since my grandpa bought it new and I have the original warranty info on it. I searched the part number online and found an overstock company selling hundreds of them with factory Ford tags.
Yea sounds like your grandpa must have had a vibration with the hubs locked in, mentioned it to the dealer, and they did the TSB repair/upgrade. Not unusual at all. So you'll be able to just buy an overstock new driveline and be on your way then? Nice easy solution if so.