one2nine

iTrader: (1)

So ever since I've lifted (rcx 6") I've been plagued by this front 4wd clunk. The lift was installed correctly per rcx so I ruled that out. Checked the iwe's and even replaced them just to rule out as well. The only thing I can relate it to is the front driveshaft. My transfer case is not 100% in alignment with the front differential and has the shaft slightly cocked. To me it's almost like the transfer case needs a drop or an indexing ring to bring it down. Almost positive my clunk is the cv binding then unloading. Any of the lifted guys had this issue. A while back someone on here had my identical symptoms with the same lift, but the thread went cold and no solution was found.

one2nine

iTrader: (1)

This is the referenced thread. Clunking is worse when backing up or turned. The clunk seems to be midline of the truck rather than lateral which makes me want to rule out an axle cv.

https://www.f150forum.com/f4/clunkin...-drive-133243/

jp360cj

Pull the front driveshaft and lock in 4x4. If it goes away then the problem is in the front driveshaft or alignment thereof. Inspect the shaft while its out. I don't know what angles these CVs can operate at, but if you find that out then you can determine if the angles are out of spec.

one2nine

iTrader: (1)

I'll probably pull the shaft sometime next week and go from there

kidastra

iTrader: (1)

I had a horrible clunk with my 4" when turning in 4x4 it was most apparent, but sometimes it would happen even in a straight line when moving from a stop. I never did find the problem but I always suspected the axle binding, truck was returned to the dealer before I could find it. I never really tried to find it to be honest

one2nine

iTrader: (1)

I guess once I pull the driveshaft I'll be able to tell if it's the axle or driveshaft binding.

Turfguy

I had done an 8" Rize lift on my 2004 F-150 and remember that they warned you to have a new front drive shaft made or purchase one from a lift dealer. They warned you that driving the truck in 4-wd over 40 mph like it was currently set up would result in damages to the drive shaft and possible other items in the surrounding area. I remember they did give you a temporary fix that involved turning the way the shaft and transfer case was bolted to releave some of the issue but not to drive it in 4wd over 40mph.

I do not know if this may be your problem but it may be a place to start looking. At the time I had pegged Rize lift kits as the best on the market due to the way their kits kept all of your normal components in their proper alignment. The shop that did my front end alignment told me it was the best lift kit they had ever seen and the easiest to get aligned.

dieselhunter44

Is there a possibility that the driveshaft spacer that was supplied with your kit is not 100% true? if it was not torqued evenly it could be warped causing the popping noise

one2nine

iTrader: (1)

It appears that the drive shaft is at an angle kinda like this \ from the t case to the differential. I had looked into a custom shaft, but I'm still not sure that would help my problem.

Turfguy

They sell a drive shaft that has a knuckle much like a cv joint that will take the stress out of it. There not cheap but if you blow the u-joint in your current shaft it can be very expensive, depending on which side of the shaft it blows. U-joints can only take so much stress before blowing. We use the CV shafts on PTO driven cutting units behind our tractors other wise my operators would take to sharp of a 180 degree turn and blow the shaft apart.