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When engaged I seem to have full four wheel drive but when I decelerate I get a "clunk clunk clunk" how bad is it? It is an IFS with auto lock hubs. I did notice that the front shaft could be bumping the crossmember that was not made for this particular application as some one torched out a relief for the shaft but I would extend it some more.
Brent
Well it could very possibly be your incorrect cross member. Under an acceleration it could be flexing the cross member into a position where the driveshaft (or did you mean axle shaft) is not rubbing, but then flexes back to a rubbing position when you decelerate. It is also very possible that the problem is in your hubs, those autos are TROUBLE! I would replace them with manuals first chance you get, mine got me stuck in a snow storm and ended up costing me $450+ for a tow and some chains. Not fun.
Shaft in question is the front drive shaft exiting the transfer case. While I do not have to worry about being stuck in a snow drift but I do intend to swap out the hub locks asap...
Brent
Seems strange that your driveshaft would be rubbing the cross member... Why were the wrong cross members swapped into your truck, seems kind of stupid huh?
Good call on the hub swap, you'll be glad you did it. Go for Warn or Mile Marker if you want a good solid set. Ford uses Warn manuals on their trucks from the factory.
The truck has been changed to auto from manual, I do not know what original power was but it was efi.
Everything was done pretty right... some things were less than perfect but it is no butcher job at all...
Brent