Ford Ranger Forum - Forums for Ford Ranger enthusiasts!

Go Back   Ford Ranger Forum - Forums for Ford Ranger enthusiasts! > >
Forgot Password? Join Us!

Welcome to Ford Ranger Forum

Reply
 
Thread Tools Search this Thread

  #16  
Old 12-22-2012, 10:25 AM
pgk pgk is offline
07 FX$ Level II
 
Join Date: Apr 2012
Posts: 169
Default Re: Clunks in 4x4 while driving

Thanks vulcan, I'll make sure to check those.
Reply With Quote
  #17  
Old 12-22-2012, 04:47 PM
Gibby1234 Gibby1234 is offline
2006 Ford Ranger 4x4
 
Join Date: Oct 2011
Posts: 180
Default Re: Clunks in 4x4 while driving

Along with the noise on my truck, it pops out of 4x4, In the new year I plan on puling the transfer case out of my truck and inspecting it. hopefully finding something wrong.
__________________
2006 Dark Shadow Grey Sport Extended Cab 4x4 - 4.0L V6 - 5 Speed - 4.10 gears
31x10.5 Goodyear Wrangler Duratrac's (Summer) - 265/75 Cooper Discoverer M+S (Winter) - 15" Dick Cepek DC-2's
Toolbox and Access Tonneau Cover - Lightforce Striker 170 Lights - Level II Tow Hooks
Build Thread
Previous Vehicles: 2002 Red Ford Ranger Edge 4x4 - 1997 Arctic Green Ford Thunderbird LX
Reply With Quote
  #18  
Old 12-26-2012, 10:16 PM
pgk pgk is offline
07 FX$ Level II
 
Join Date: Apr 2012
Posts: 169
Default Re: Clunks in 4x4 while driving

Hey man, I don't think mine is popping out of 4x4, if it is its not registering on the dash light and its not affecting traction. When it does it under throttle I don't skip or skid at all. I tried timing it on the highway into town the other day and it was clunking every 5 or 6 seconds at 90-100kph. I'm taking her to the shop tomorrow so hopefully by the weekend I'll know what's going on.

Would it be possible to have a low fluid level in the front diff that would cause the CV's to bind? I'm not entirely convinced its transfer case at this point.
Reply With Quote
  #19  
Old 01-01-2013, 04:03 PM
Gibby1234 Gibby1234 is offline
2006 Ford Ranger 4x4
 
Join Date: Oct 2011
Posts: 180
Default Re: Clunks in 4x4 while driving

This morning I pulled the transfer case out of my truck and opened it up, hoping to find the problem. It was in surprisingly good condition, I was no able to find anything obvious that could cause the issues of popping out of gear. I found a little bit of wear from the gear that was popping out, but not enough to cause any issues, and a little bit of wear on the Cam and shift fork. Tomorrow i am heading to the ford dealer to pick up a new cam and shift fork. Hopefully that fixes my problems. I will report back.
__________________
2006 Dark Shadow Grey Sport Extended Cab 4x4 - 4.0L V6 - 5 Speed - 4.10 gears
31x10.5 Goodyear Wrangler Duratrac's (Summer) - 265/75 Cooper Discoverer M+S (Winter) - 15" Dick Cepek DC-2's
Toolbox and Access Tonneau Cover - Lightforce Striker 170 Lights - Level II Tow Hooks
Build Thread
Previous Vehicles: 2002 Red Ford Ranger Edge 4x4 - 1997 Arctic Green Ford Thunderbird LX
Reply With Quote
  #20  
Old 01-05-2013, 12:51 PM
Gibby1234 Gibby1234 is offline
2006 Ford Ranger 4x4
 
Join Date: Oct 2011
Posts: 180
Default Re: Clunks in 4x4 while driving

SOLUTION: My Transfer case is Fixed! Here is what if found wrong, and what parts i replaced to fix the problem.

It took me and one other guy around 3 hours to get the transfer case out, most all the bolts had lock tight, and there was no room for a ratchet, so it was a box wrench and a 1/4 turn at a time all the way off. The rear driveshaft had to be completely removed, and the front one just disconnected from the transfer case. Here is what we found wrong:

The Cam inside the transfer case had some wear, as seen in the top center on this image:


The Plastic Shift fork also had some wear:


Then the two gears that were skipping when i heard the thump noise:




Here are some other pics of the transfer case apart on the workbench:




__________________
2006 Dark Shadow Grey Sport Extended Cab 4x4 - 4.0L V6 - 5 Speed - 4.10 gears
31x10.5 Goodyear Wrangler Duratrac's (Summer) - 265/75 Cooper Discoverer M+S (Winter) - 15" Dick Cepek DC-2's
Toolbox and Access Tonneau Cover - Lightforce Striker 170 Lights - Level II Tow Hooks
Build Thread
Previous Vehicles: 2002 Red Ford Ranger Edge 4x4 - 1997 Arctic Green Ford Thunderbird LX
Reply With Quote
  #21  
Old 01-05-2013, 01:04 PM
GT2hot4u GT2hot4u is offline
'06 ranger fx4 lvl2
 
Join Date: Oct 2012
Posts: 12
Default

Wow good job!! Looks like a lot of work..
Reply With Quote
  #22  
Old 01-05-2013, 01:25 PM
PHAL23 PHAL23 is offline
Ranger Gang
 
Join Date: Mar 2012
Posts: 679
Default

Man I hope this isn't my problem. Cause mine skipped like yours did...I don't know about taking my whole tcase apart. That's a bit sketchy for me.

Sent from my iPhone using FRF App
__________________
2005 Ford Ranger Edge 4x4
3.0L, Air box mod, Torsion Cranked, 2" Leaf Blocks, 31x10.50-R15's on American Racing Wheels, Tinted Windows, 10in Pioneer Sub w/ 250watt Rockford Fosgate Amp
Reply With Quote
  #23  
Old 01-05-2013, 01:28 PM
Apollyon214 Apollyon214 is offline
Oh! I am no! >.<
 
Join Date: Jan 2010
Posts: 167
Default

Wow awesome

How difficult was this? Do you have experience doing this or were you using any literature or online reference to guide you?
__________________
Mods: Engine delete (??)
Reply With Quote
  #24  
Old 01-05-2013, 01:43 PM
Gibby1234 Gibby1234 is offline
2006 Ford Ranger 4x4
 
Join Date: Oct 2011
Posts: 180
Default

My dad was a heavy duty mechanic, so I had him helping me. I have some mechanical experience, I took a couple mechanics courses in high school and work on tractors regularly. It wasn't nearly as difficult as I thought it was going to be. It took two guys to take the transfer case out as we didn't use a transmission jack. I have the Haynes manual, but it didn't help too much. I used the web site that I posted earlier as a reminder as to what order the pieces all go back in. The key to doing this is remembering how it goes back together and extreme cleanliness. All the gaskets have to be scraped off (one of them was so stuck on we had to use a air rotary tool and a wire wheel to remove it, which left dust everywhere we had to clean off). It was kinda tricky getting everything lined up with wet gasket maker when we were putting it back together. I had a shop estimate of $1600 to fix it, and I did it myself in about 7 hours and $255 worth of parts. No special tools, just some box wrenches, socket set, scraper, air rotary tool (not needed but made the gasket removal much easier) jack and jack stands.
__________________
2006 Dark Shadow Grey Sport Extended Cab 4x4 - 4.0L V6 - 5 Speed - 4.10 gears
31x10.5 Goodyear Wrangler Duratrac's (Summer) - 265/75 Cooper Discoverer M+S (Winter) - 15" Dick Cepek DC-2's
Toolbox and Access Tonneau Cover - Lightforce Striker 170 Lights - Level II Tow Hooks
Build Thread
Previous Vehicles: 2002 Red Ford Ranger Edge 4x4 - 1997 Arctic Green Ford Thunderbird LX
Reply With Quote
  #25  
Old 01-07-2013, 11:46 AM
pgk pgk is offline
07 FX$ Level II
 
Join Date: Apr 2012
Posts: 169
Default Re: Clunks in 4x4 while driving

I don't know exactly what was wrong with mine yet. The shop pulled it out and replaced it with one from the autowreckers that had 21,000k on it and that fixed my clunk. Just drove it 3000km home with no issues. Last I talked to them, they were going to start tearing apart my old one and see what was wrong with it. They do tcase rebuilds so they'll find out for sure.

One of the things mentioned to me a couple times was that the bar that holds all the forks/etc (the bar in the bottom of the last pic) is steel and the housing it sits in is aluminum. As it wears, if it gets any wobble in it, it can elongate the hole it sits in in the aluminum housing and that will cause the forks/etc to slip in and out under load. Not sure if that was part of it or not.

I don't see anything that looks really bad in your pics, you just replaced the cam, shift fork and two gears?? That's a big job man, good work. Outside my skill set for sure haha.
Reply With Quote
  #26  
Old 01-07-2013, 12:58 PM
desjardo desjardo is offline
Ford Ranger Driver
 
Join Date: May 2010
Posts: 501
Default Re: Clunks in 4x4 while driving

so you replaced, cam, fork and the gears?
Im having same issues.
__________________
2006 Ranger FX4 Level 2
33x12.5 Hankook Dynamic M/T, Ion Aluminum Alloy 15x10 -4inch offset,Front winch bumper, superwinch ep9.0, 3" B/L, Torsion Crank, Chrome Bed Bar, 2 x 100 watt offroads, 6000k HID Heads/Fog(s), Pioneer H.U., 12" Jackhammer, Alpine mrp 500,train horn, whelen pa/siren
Mods
Headlight, Fog, Airbox, Blue led interior(not gauge cluster yet), blue led l/p, blue led side markers, color match skid plates
To come
sliders, suspension lift, rear bumper, tire carrier, tailgate
Reply With Quote
  #27  
Old 01-07-2013, 01:51 PM
Gibby1234 Gibby1234 is offline
2006 Ford Ranger 4x4
 
Join Date: Oct 2011
Posts: 180
Default

The main piece that was worn was the cam, it's kinda tough to see it in the picture, I'll try to take a better one. On the new cam, the bottom of the one slot was flat, and the one I took out had a rounded bottom, it had worn almost an 1/8" off the cam where the shift fork sat while in the 4 high position. I think the previous owner of the truck used 4x4 all the time to cause this much wear in only 90,000 km. (56,000 miles). I then replaced the shift fork and the two gears that were skipping just cause they had minor damage.
__________________
2006 Dark Shadow Grey Sport Extended Cab 4x4 - 4.0L V6 - 5 Speed - 4.10 gears
31x10.5 Goodyear Wrangler Duratrac's (Summer) - 265/75 Cooper Discoverer M+S (Winter) - 15" Dick Cepek DC-2's
Toolbox and Access Tonneau Cover - Lightforce Striker 170 Lights - Level II Tow Hooks
Build Thread
Previous Vehicles: 2002 Red Ford Ranger Edge 4x4 - 1997 Arctic Green Ford Thunderbird LX
Reply With Quote
  #28  
Old 01-07-2013, 02:54 PM
pgk pgk is offline
07 FX$ Level II
 
Join Date: Apr 2012
Posts: 169
Default Re: Clunks in 4x4 while driving

Definitely designed for the weekend warrior and not those of us that actually need 4x4 for daily travel!

How do you like your duratracs? I wanted them but couldn't justify the additional pricetag over the Duelers that I got for $900...
Reply With Quote
  #29  
Old 01-07-2013, 08:05 PM
Gibby1234 Gibby1234 is offline
2006 Ford Ranger 4x4
 
Join Date: Oct 2011
Posts: 180
Default

Well my 2002 ranger had 150000km when it got totaled, and it still worked awesome and it spend a lot of time 4x4ing. I'm is Saskatchewan, so I know how important 4x4 can be. And yes, I love my Duratracs. They are awesome in mud and snow and aren't very loud on the highway. They are not the greatest on sheer ice though, but other than that I am really happy with them. I've out around 20000kms on them so far on two different rangers. I bought them for $1100 including tax and installation.
__________________
2006 Dark Shadow Grey Sport Extended Cab 4x4 - 4.0L V6 - 5 Speed - 4.10 gears
31x10.5 Goodyear Wrangler Duratrac's (Summer) - 265/75 Cooper Discoverer M+S (Winter) - 15" Dick Cepek DC-2's
Toolbox and Access Tonneau Cover - Lightforce Striker 170 Lights - Level II Tow Hooks
Build Thread
Previous Vehicles: 2002 Red Ford Ranger Edge 4x4 - 1997 Arctic Green Ford Thunderbird LX
Reply With Quote
  #30  
Old 01-07-2013, 10:18 PM
02RangerFX4 02RangerFX4 is offline
Lil' Red
 
Join Date: Jan 2011
Posts: 6,369
Default

Quote:
Originally Posted by Gibby1234 View Post
SOLUTION: My Transfer case is Fixed! Here is what if found wrong, and what parts i replaced to fix the problem.

It took me and one other guy around 3 hours to get the transfer case out, most all the bolts had lock tight, and there was no room for a ratchet, so it was a box wrench and a 1/4 turn at a time all the way off. The rear driveshaft had to be completely removed, and the front one just disconnected from the transfer case. Here is what we found wrong:

The Cam inside the transfer case had some wear, as seen in the top center on this image:

The Plastic Shift fork also had some wear:

Then the two gears that were skipping when i heard the thump noise:

Here are some other pics of the transfer case apart on the workbench:
I would recommend changing the fluid in the Tcase more often. That might be whats causing all that wear due to you using 4x4 frequently.
__________________
2002 ford ranger FX4 Off Road | 4.0l v6 | Flowmaster 40 S/I D/O | JBA Headers | Rebello Racing cams | port and polished heads | K&n Drop-in filter | TwinStick | 31 Spline 4.10 Torsen rear diff | Alcoa rims | Sitting on 31's|
Reply With Quote
Reply

Thread Tools Search this Thread
Search this Thread:

Advanced Search


Similar Threads
Thread Thread Starter Forum Replies Last Post
trans clunks and whistles edenq Drivetrain Tech 3 08-13-2012 08:37 AM
16 and driving out 0111001001100011 Introduce Yourself 30 11-19-2011 07:56 PM
Winter Driving Blairsville1946 General Ford Ranger Discussion 52 11-05-2011 08:08 AM
manual clunks while shifting SalRanger2 Drivetrain Tech 16 07-09-2011 10:19 PM
For Sale: 2 running and driving Ford Rangers 98 & 00 both 4x4 CSMonte Trucks 5 01-04-2011 05:43 PM