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I have a 94 ranger 4x4 4.0 auto. I bought it used and have a problem in the front axle. It feels like it is binding when its in 4wd and in 2wd, when I turn left, it clunks or clicks, just does not feel right. I have changed the radius arm bushings, ball joints, installed warn lockouts, checked brakes, rotors, u-joints, etc. The front pig is full of CLEAN oil. I am at a loss. Almost like the pig is shot or the gear ratio is wrong in one of the axels. The door tag says its a 91 code. I havent been able to find my manual to see what that is. BUT, I do know for a fact my speedo is off by 10 mph. When my speedo says 45, I am actually going 55. Other than that, I have no problems. I just dont like running in 4wd or even leaving the hubs engaged. It just makes way too much noise, even with the hubs engaged and NOT having the transfer case engaged. Its just a plain, stock truck, 15" wheels, 235-75 tires (newer).
You say that the problem is only there when the hubs are engaged. Is this true? If so, the problem can then be narrowed down to the front driveline.
Then you said the truck does this even with the transfer case in 2wd, which makes me think the transfer case is probably OK. If I were you, I'd take the front differential apart and check it first. You changed the oil in there right? But that won't help anything if the previous owner already toasted the gearing inside. Open that front pumpkin up and see how things look. After you go through the front differential, if the problem still exists, then I'd say maybe transfer case...but that would be unlikely.
OH, and I forgot. Usually your speedo being off like that is a result of tires that are larger than stock size. But you have 235/75s, right? So then there is something else causing the driveline to turn at improper speeds....this would also lead a person to think gearing in the differential has been changed. On a 2-wheel drive this would be no big deal. But on a 4x4 if someone has ever tinkered with gear ratios they could have really messed your truck up. You have to have specific ratios in both pumpkins, and they have to be co-ordinated with each other and for your specific truck in order to function smoothly.
Have that differential checked out just in case that's the problem. You don't want to burn that puppy up I can assure you.
i think that we can rule out the gear ratio bein split. if it does it in 2wd then the gear ratio will not matter because the t-case isnt locked in. the ONLY time things will bind up with a split gear ratio is if the t-case is locked in. im led to beleive that one of yer hubs is always locked in, but you said thet you installed new warn hubs. so that rules them out unless by pure coinsodence somethin is wrong with one of them. id still double check the hubs, u-joints, bearings, etc...
I was kinda leaning on the rear end being changed. I think I might have time tomorow to crawl under it and check the axel tags. Could be as simple as a bent axel shaft (been there, done that) But, the secret life of used trucks, anyhting could be possible in its previous life. The door sticker says it came with 237/75/15 and thats whats there. The speedo being off, the frong end bind, etc. I think I might want to start looking for a new ring set. Anybody got a good reason NOT to put in 4.10 ? I dont care about mileage, I only drive 4 miles to my office. I am hoping to do another 302 or 351 conversion next year and the 4.10 would be a fun ratio with some 33-10.50 tires. I am up for ideas, but I know I will be using a 5 speed from a 88+ f150 4wd and advanced adapters gizmo for my xfer case and a skyjacker 6" lift. Really looking for gear ratio input.
I do not see where you said that the wheel bearings and locknuts were checked for wear and correct torque. Loose wheel bearings will make clicking noises and bind the steering.
i checked the wheel brgs as well. I am trying to decide wether or not to just buy an f150 4wd and trade off the ranger. I really miss the manual trans. I have been kinda looking for a manual trans truck. Anybody want to trade ?
Start over w/ this info an 91 axle code is 3.27 gears w/ a convention al (normal) diff. also check and see if the tires are rubbing, or something is loose (like the sway bar!!).