I have a 1994 Explorer that when 4WD is engaged and under load makes a clunking/racheting noise that comes from the driver side front wheel assembly. The hub does not seem to be locking or something is slipping within the hub. Oh, I changed the front rotors before this started happening. Any pointers would be greatly appreciated.

 

Certainly sounds like something wrong with the hub. When you installed the hub with the rotor change, was the hub full of grease? There should be almost no grease inside the hub. Too much grease can cause the hub to not want to engage.

 

When I took the hub apart there was quite a bit of grease in there, I made sure there was plenty when I put it back together (like a good back yard mechanic). One more thing, it is not just a noise you can feel it clunk.

 

A Lee Miles local tranny shop rebuilt the trans in my '92 Explorer. I'm starting to regret letting them touch the truck. This will be the second time I had to bring it back. The first time was because the truck wouldn't go anywhere in reverse if you were trying to back up on a hill. They "fixed" that, blaming it on a defective part. Now I have this 4x4 problem I noticed when we got 10 inches of snow.

 

I wouldn't think they would have touched the hubs but who knows. I wonder if they may have messed with the electric motor that engages the hubs?

 

While the truck was still in 4x4 high, I jacked up each front wheel and tried to spin them. Both were engaged, I could not spin them. I could see each drive shaft turn a tiny bit back and forth as I tried turning it's wheel back and forth. So this leads me to believe that the hubs are OK and there's something wrong with the transfer case. I know they had to remove the transfer case to get the tranny out. I didn't check the fluid in the transfer case, I guess I should tomorrow. Any idea what they could have screwed up? As you now suspect, I don't trust the one bit. And if I had a clue what was wrong, I could prevent them from screwing me even more.
Thanks,
Joe

 

At one time I had clunking coming from the front when driving in 4x4. I also would clunk and slip in the yard (in snow). I took it to the dealer and said the hubs needed replaced. So I let them do it. I guess that was the problem because it has not done it since.

 

mrshorty also suggested that it may be the axle needle berings. I guess I'll take it all apart and service as much as I can. Although, the hub problem would be the easiest to repair. Maybe I'll try that first. We're getting hammered by snow right now! It's a bad time to have problems like this now :-(
Thanks for the reply,
Joe

 

A real bad time but a blessing in disguise, I sold the vehicle to a friend and since the 4WD is not working she does not bring it up my long and steep snow covered driveway, the one time she drove her husbands blazer up she turned it on it's side, would have hated to see the Explorer on it's side....As soon as the weather breaks I will pull it apart and see what I find..thanks for all the replies!

 

Mine sounds like you describe how yours is acting. Do you really think it's the hubs? All that clunking under the floor board? I hope so, the hub repair would be much easier than axles. Keep me posted how you make out and I'll do the same.

 

Here's the scoop:
The grinding/clunking noise was the front driveshaft that exits the transfer case. Ford calls it the front propeller shaft. The shop (Lee Myles) that rebuilt my tranny, replaced it with a used one for $127 plus $60 for labor a toatal of $187. A new one would have costed $515, just for the part. I know the shop gave me a decent deal after checking all over the web.
Hope this experience will help others in the future.
I want to thank everyone for their input.
Later...
Joe