4x4 clunking...kinda

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Oct 20, 2006 | 01:12 PM

BillyBob69

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From: Wheatland, Mo

4x4 clunking...kinda

2002 F150 XLT, 4.6L V8, 4x4. 114K miles. Manual T case. Runs like a dream Never an issue....until now...kinda. I use the 4x4 pretty regularly in the winter and someitmes in the summer when it rains..(muddy property). I have noticed over the last few months in the 12 or so times that I used the 4x4, I hear and feel a "CLUNK", up to about 3 of them when the 4x4 engages. It is coming from the front end. I will drive until I can't go any further, stop, pull it into 4hi and then ease into the gas. And everytime, I get at least 1 clunk. Once it is fully engaged, it works great. no weird sounds, binding or anything. Just while it is engaging.

Normal or not?

Oct 20, 2006 | 01:45 PM

stephen.osborne1

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Joined: Sep 2005

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From: Montana

I'd check the fluid level, but in the manual it says a clunking noise is normal during engagement.

Oct 20, 2006 | 01:46 PM

BillyBob69

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From: Wheatland, Mo

T-case fluid i take it?

Oct 20, 2006 | 08:17 PM

steve(ill)

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i think the clunk is the engagement pin lockin gin. thats normal. mine does it also. works great, just has 1 clunk to lock into gear.

Oct 22, 2006 | 12:55 PM

kanarman

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From: an a happy place

ok i have a question i removed my diafram from the front on mine because itwould pop out at random. i took it to a shop and they saw some plastic shards in the front diff and put it back together i bought a new diafram for it and still didnt work .
i now go enderneath the truch and turn the front drive shaft and fully enguage the leaver . is there a real fix for this?

Oct 22, 2006 | 04:50 PM

kspilkinton

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Joined: Jul 2001

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From: South Kitsap County, WA

Somebody posted up the manual engagement assembly that's available for the front diff a while back. That may fix the engagement issue. As far as plastic shards in the diff, itself... you got me there. Generally it's a shift fork issue, and it seems - if you're engaging it by hand - not to be the problem.

-Kerry