As far as the rear end goes, the steel drive shaft was replaced with a one piece aluminum shaft.

 

the drive shaft replacement was an attempt to eliminate the drive line clunk of the slip yoke binding
the FX4 rear end replacement was on the original Torsen rears that came standard that year on FX4 Rangers

 

So, is the chain rattle something that will cause problems, or is it just an annoying noise? I imagine that it will take quite a bit of work to replace, and I would like to put it off for warmer weather if it is not imperative.

I checked on my driveshaft, and being that it is the XLT, I believe that it has the aluminum drive shaft.

 

The chain rattle will get worse, Ford is having guide issues in that they are wearing out due to poor material construction. I've had a couple trucks come in on the hook cause the guide broke off completely and jamed in the chain. I've also seen pieces get jamed in the oil pump chain and ended up breaking this chain causing other failures due to no oil pressure. Just a heads up not to let it go too long.

 

Should Ford not be recalling this problem, being that so many are having issues with it? If it is a problem with poor craftsmanship (though I am sure that Ford will not admit that) then it seems to me like it should be recalled! what would something like this set me back if I had the dealer do it?

 

well the reason its not a recall "yet" is that Ford looks at how many are being repaired under the TSB. If the # is high they will issue the recall. I know that sucks but I was told this from a Ford rep.

TSB: 04-15-04
"rattle" noise from 2000-3000 rmp in 4.0L sohc at 40mph.

Part kit #: 2U3Z-6D256-DA
all Rangers 2000-2003
This kit will include new chain & gears and revised guides, Timing cover gasket is the only gasket in the kit. Might want to replace waterpump gasket while you are in there.

Est. Time for repair: 5.8 Hours(this is warrenty time mind you)

 

A BIG THANK YOU out to all those who replied, you all have been a great help to me, looks like i have some repairs to get to, THANKS again!