Ok So I took my truck in on Thursday and they kept until Friday evening, and they could hear the sound coming from the transfer case. So they swapped out the transfer case with a new truck on the lot with the same set up as my truck, but the noise is still there. My friend thinks that it is a faulty drive shaft and thats why the problem hasn't went away. So my question is could a faulty drive shaft cause this problem?

Here is a video of the noise it was taken by the front drive shaft, listen to the whole video, click on the picture or the link to watch!

http://s1303.beta.photobucket.com/us...fe73b.mp4.html

 

Anyone?

 

That is a strange sound to be sure. It sounds halfway between a "rubbing" and a "warped" sound to me. Nice video footage by the way. I am not a mechanic by any means, but is the shaft supposed to stretch out like that when you accelerate? I can see that black line on the shaft that looks like some residue. Is that a sign of a leak? Is the dealership going to swap out the drive shaft next?

 

I'm no mechanic either, but it appears that the disc on the right is warped, especially when ur slowing down. Could maybe be something with that.

 

I'm not sure i tried bringing that up but no answer on that yet

 

They just replaced the drive shaft yoke which is what your looking at and that why I brought up the drive shaft but no answer if they are going to replace it yet

 

You said they replaced the transfer case but do you know if they looked at the differential? I know ford had a huge problem with differentials in the older explorers and never confessed it. My sister actually had to get the differential in her explorer replaced because it was making a noise similar to the one in the video.

 

It sounds to me me too like a rubbing or scraping of metal on metal. Or like when a bit of sand gets stuck between brake pads and rotor. The good thing is that it should clearance itself with time. The bad thing is that the metal produced could ruin bearings or even the whole transmission if it were in there.

If they can not find the source, I'd ask them to give you an extended warranty (120k miles or so) and just wait until it either goes away or causes a failure.

 

Local dealer had an '08 with a bad "#9 touring bearing" in back of the tranny case. Sounded similar to what you had posted in the video when I showed him. Different generation vehicle, but when the transfer case was replaced on this '08, the problem wasn't fixed. Not sure if this helps, but maybe another avenue to explore?

 

Ok thanks guys ill let the techs know, I just hope they listen to me.