So I've searched and read thread after thread but can't believe that I can't really find a relative thread from someone who has had the same issue.

I have a 94 2 wheel drive with the I-6 / E4OD combo. Recently I've notice when I change into drive gear most of the time that there is a loud clank/clunk sound which seems to be coming from underneath and to the rear.
Tonight I had the drivers side rear wheel jacked off the ground and turned the wheel till the gears stopped it and then the other way and found the source of the clanking. It only happens in one direction and it seems that If I push the wheel gently till it stops...no noise but then give it an extra push and thats when it clanks. The drive shaft also moves a touch more when it makes the sound. The sound seems to come right from where the drive shaft goes into differential. I realize there is a U-joint there but it does seem tight. It is quite loud though and sort of sounds hollow if ya know what I mean. It doesn't sound like it's coming from inside the diff though....but I think this because logic tells me that gears submersed in gear oil would not clank like that. Also just checked oil in diff a few days ago...topped it up but it did not take much.
Hoping this is sounding familiar to someone and they can tell me what is making the noise.


Anyone got any helpful suggestions on any other checks I can do to eliminate certain parts

Also while doing this I noticed that the axle had play in and out(push/pull) ...is that normal???

 

The U-joint is bad. The bearings inside one or more caps have failed. Replace the U-joints.

 

Hey Clubwagon,
thanks for the response....
Since U-joints are fairly cheap, I will likely replace it tomorrow to rule that out. Though while manually turning rear wheel/making the clanking sound I put my hand around the whole joint and both side of joints seemed to move together when it moves/clanks.
Also, would it be that loud.
I'm not trying to shoot down your idea here.....I am just asking questions...
Thanks,
Dave

 

That's what it sounds like. A problem with the diff wouldn't do that. The only other thing I can think of is if the yoke is loose.

 

Naaawww. A limited slip diff will clank like that, especially if the clutch packs are worn out. There is a spring in the middle of the carrier that loads up the clutches. If they are gone, things get a little sloppy in there.

 

Ok...so.....bought the rear u-joint but did not get it changed. the four bolts that connect the last u-joint to the rear axle are stripped from the last person who replaced it I guess. I tried to see if I could bang it out..but it seemed pretty tight in there. I will wait and get new bolts to put back in once I get the old ones out. I ended up doing some needed body work instead. I will try to find the bolts tomorrow and give it another go. Would It be best to go to a Ford dealer for them or maybe a junkyard.

NWBronco...This is much louder than the usual clunk that you refer to. This has a louder clanking. It is like the sound is resonating through the drive shaft. It is like someone is hitting the hollow shaft with a hammer....Almost the same sound. OH...and it's not limited slip.

I still think the u-joints look sound but will find out tomorrow I hope.
I'm gonna pull cover on diff and take a look as well. I was gonna today but found a boken bolt on that as well so have to find another replacement bolt and remove the broken one from the diff. Not that I know what to look for but once I have the cover off I will inspect and snap some shots of anything that looks funky and post them here.

In any event, I will update tomorrow as to my progress.
Dave

 

Good luck with it. And post up what you find.