02 f150 4wd clunk

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Old 12-15-2010 | 11:56 PM
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02 f150 4wd clunk

Hi
I have been trying to find information about why my Father-in-laws f150 is making a clunking noise when it is in 4wd. I just happened to be riding with him during this lates Minnesota blizzard, when we left my place, he shifted into 4wd, we left my yard, hit the road, turned a corner, accelerated and clunk, clunk, clunk. 3 times over a span of 100 yards. Quickly he disengaged it as we were on a road with fairly clean pavement. Got onto a snow covered gravel road and I told him to shift it into 4wd again. He did, same thing happened. Loud clunking noise. Told him he better get it into the shop, my initial thought was that a cv shaft was bad.

He took it in this week and they told him his front differential was bad and that it was a common problem for those trucks at about 100K. He has owned it since it was new and it has around 90K on it now. They want to soak him 1000$ for this. I told him I would do some internet research on this "common problem" but surprisingly I am coming up short. What I am finding is that this seems to more likely be more of a vaccum problem, or a transfer case fork problem. He has the 5.4L with the manual 4wd shift lever. Any thoughts on what is going on. I can't seem to find any real info on a problem similar to this on any of the f150 sites so I am asking for help in the forums. I want to try and do some basic diagnostics before we turn it over to the mechanic. 4wd has worked great up until now. Thanks in advance
 
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Old 12-16-2010 | 05:36 AM
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From: Joplin MO
What year is it?
 
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Old 12-16-2010 | 08:17 AM
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2002 F150, 5.4L, with the manual 4wd shift. Thanks.
 
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Old 12-16-2010 | 03:42 PM
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Any ideas on tests I should run?

Does it sound like a vaccum situation or maybe a selenoid. I have read other threads about the 4wd not engaging and there are some tests I have read about to see if the transfer case is in gear. I am likely going try them but was hoping for more info or if anyone has seen a similar problem.
 
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Old 12-17-2010 | 09:20 PM
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i would star with u joints, sounds like that is your problem. with the truck in nuetral see if there is any play within the driveshaft, where it meets the front axle and tranfer case. if you can move the driveshaft up/down or side/side you are in need of new u joints.
 



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