transfer case clanking

[amilynx]

I have a 99 explorer. I had the tranny replaced 3 times already and the transfer case once. Now I have the problem with the wheels turning left and right, thought the calipers were sticking at first, changed those and the brake lines, we realized that the noise was coming from underneath. The noise is at the backside of the frontdrive shaft that goes to the front punkin. Any ideas what it could be? Help!!!!!!!!!!!!!

[shorod]

Welcome to the forum!

Is the noise only when in 4WD, only when not in 4WD, or all the time when turning? If only in 4WD, you're not using the 4WD while on dry pavement, are you? If so, that might explain why you've had transfer case problems before, and will likely again. Do you feel any binding, or is it just the noise?

-Rod

[amilynx]

It happens in 2wd and 4wd. It is binding. My husband said you can actually see movement in there when it clanks. We took it for a test drive and it drives fine straight but when you try to make a left hand or right hand turn is when you hear and feel the clank or popping noise and "sounds like metal on metal" when it does that.

[shorod]

It sounds like your transfer case is not releasing 4wd. I'm assuming since you say your husband has been able to see the binding, it makes the noise even if the wheels are in the air, so a u-joint may be damaged as well. However, you should fix the stuck 4WD otherwise any other repairs you make will likely be short-lived as well.

There have been quite a few threads about issues with the transfer case shift motors, you should try searching the forum for details on how to troubleshoot that.

-Rod