1994 Ford E-Series Van Rear Drive Axle Knocking

1994 FORD E-SERIES VAN
135,000 MILES • V8 • 2WD • AUTOMATIC
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LRMORRIS
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When making turns only, a loud knocking, thumping noise occurs at the back of the van. Looking for the obvious like a loose shock or exhaust system, there were no signs of a problem. Next, looked at rear axle bearing but while I was removing the axle, I had to take out the small differential gears. These gears were heavly galled, and very loose on the center shaft. Could these gears be locking up during turns and causing this loud knocking sound?

How do you inspect these gears and shaft?

Can they be replaced without replaciing the entire rear end?

Is it better to replace the entire rear end?

Thanks for your help.
Apr 2, 2008 at 7:54 PM
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MHPAUTOS
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Hi there,

With out actually viewing the gears , it is a bit hard to draw a conclusion, but i would be inclined to have the diff re built. This should bre done by a shop specialising in drive line repairs, as there is a lot more to it than just fitting gears and bearings, all preloads and back lash must be correct or the unit will fail.

Mark (mhpautos)
Apr 3, 2008 at 4:22 AM
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LRMORRIS
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Have you ever heard of a knocking noise - thumping noise coming from the differential itself?

Is it something else?
Apr 3, 2008 at 8:18 PM
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MHPAUTOS
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Hi there,

Diffs can make same very strange noises, but make sure all rear suspension components are tight and in good condition, check unis for wear, but if the diff bearings and gears are showing signs of abnormal ware , i would be concentrating there.

Mark (mhpautos)
Apr 4, 2008 at 3:22 AM
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2CARPRO JACK
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Sounds like aproblem with the limited slip unit or it may be the posi unit if so equiipped.Mark is correct about having a shop that does diffs do your work
Apr 4, 2008 at 7:38 AM