"Clunk" (T-case)

Denisefwd93 · Apr 14, 2017

Feeling a bit defeated.. not quite ready to start working on the beast as I'm hoping to sell my collector car for some additional $ and the "bad" auto is still shifting kind of ok.

Anyway, got the "feeling" it was stuck in 4wd (93, 4.0 auto long bed) the other day.. back up..park, fwd.. and it seemed ok.. next morning it "feels" like it's in 4wd again.. At the intersection red light and slight hill I did the same routine.. (no cars behind me) green light I made a left turn.. CLUNK! under the drivers seat for sure. but the steering seemed lighter so I assumed it popped out.

I don't have manual hubs (yet) Which ones should I get? Rugged Ridge?

Lights work and 4L works, although when cold, it's slow to go into 4wd hi or lo.

Worried the Clunk was the T-case internals breaking. so I'm a bit hesitant to try 4wd again.

Hoping it's the shift motor :dunno:

On a tight left turn I do always feel/hear binding or scrubbing even if not in 4wd. could that be the limited slip differential?

Did a gravel test . only the back wheels spun yesterday.

I do read the tech sections

Happy Easter all!

adsm08 · Apr 14, 2017

Could be locked up front U-joints. If the auto hubs aren't disengaging correctly those can cause all sorts of issues.

85_Ranger4x4 · Apr 14, 2017

I would go Warn for hubs.

If you are not stuck on new U-Pull-It around me gets $10 a pair for hubs and they don't care if you have the conversion bits or not... so I would try a yard near you.

Denisefwd93 · Apr 14, 2017

I'll try some yards but leaning towards new. I did realize when my "trusted" garage guy did the front brakes and found a badly warped rotor he packed the auto hubs with grease and reading the tech page says use ATF I'm like duh?

Warn... ok.. better quality? I'm not going to be rock crawling only expect to use the 4wd in bad weather and maybe a fishing trip in the woods.

Thank you gentlemen

Denisefwd93 · Apr 15, 2017

Well it seems Summit has about the best price on Warn standard hubs and even the conversion kit is reasonable

Andy D · Apr 16, 2017

Heh heh, The Rat's manual locks are original The chrome is peeling off the ABS plastic. They work great. Their ugliness is typical of the Rat's "ratty-ness" . I don't get why Ford ever offered manual hubs on a shift on the fly 4WD. It doesn't matter. I have to go underneath and shift then wire the TC into place. I don't care. When I lock the peeling hubs, I know that it is in 4wd. Pushing a button to shift the TC is an act of faith. Centrifugal hubs aint rocket science either. I had a Willys with them. I had AMC Grand Wagoneers for 20 yrs too. Vacuum is simple and cheap. mostly jeeps suffered from rotten hoses. I can only imagine what could happen to a Ford engineered vacuum hub.

Denisefwd93 · Apr 18, 2017

I have a Dana 35 with 27 spline? should be according to Warn.com site.
https://warn.com/truck/hubs/application_chart.jsp

Guess I'm going to have to do something pretty soon, it clunks and buzzes like a ratchet. backup seems to lock the driver's side not unlock it

Denisefwd93 · Apr 25, 2017

Well have a set of NEW warn standard hubs. I don't like the how the outer lock nut only relies on torque and friction to keep it tight with the inner lock nut. My ole friend is going to help me get these things installed this week (if it ever stops raining)

There is an outfit called "stage 8" that makes a locking setup for the dana 35. but at nearly another 100 bucks. I hope I don't "need" it.

The tech pages did show that the older warn hubs had set screws on the outer locknut!

Denisefwd93 · Apr 26, 2017

Update: the right side auto hub was culprit butt: got a bad lower ball joint so on it goes

turbo91xlt · Apr 26, 2017

Andy D said:
Heh heh, The Rat's manual locks are original The chrome is peeling off the ABS plastic. They work great. Their ugliness is typical of the Rat's "ratty-ness" . I don't get why Ford ever offered manual hubs on a shift on the fly 4WD. It doesn't matter. I have to go underneath and shift then wire the TC into place. I don't care. When I lock the peeling hubs, I know that it is in 4wd. Pushing a button to shift the TC is an act of faith. Centrifugal hubs aint rocket science either. I had a Willys with them. I had AMC Grand Wagoneers for 20 yrs too. Vacuum is simple and cheap. mostly jeeps suffered from rotten hoses. I can only imagine what could happen to a Ford engineered vacuum hub.

Manual hubs only came factory on manual transfer case RBVs. A previous owner converted the truck over to manual hubs.

Denisefwd93 · Apr 29, 2017

adsm08 said:
Could be locked up front U-joints. If the auto hubs aren't disengaging correctly those can cause all sorts of issues.

Now that we are getting into the work. I actually found that the right auto hub was locking few and rev making clicks weird, I thought it was the left But, that would cause the other end axle to spin in reverse right?

"Clunk" (T-case)

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