2004 Ford Explorer U-joint noise from back

2004 Ford Explorer

When I shift my car in reverse I hear a loud kick back kind of like knicking coming from the back tires



There are different things that make different noises. Noises are one of the most difficult issues to describe and sometimes locate. Instead of just guessing, which is about all you can do without actually looking at it, we will focus on the most common cause.

The universal joint(U-Joint) going out would be the most common cause for this sort of issue. Eventually you will heard the noise when moving from forward to reverse and from reverse to forward as they get worse.

DRIVESHAFT U-JOINT, Replace

Single Cardan, Slip Yoke

Disassemble

Do not, under any circumstance, clamp the shaft in the jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing shaft failure during vehicle operation. Place the shaft on a suitable workbench. Do not damage the tube. If components are not marked and installed incorrectly, driveline imbalance can occur.

1. Index-mark the shaft components.

2. Remove and discard all four snap rings.

3. Clamp bearing cup removal tool No. 205-086 or equivalent in a vise.

4. If necessary, use a pair of pliers to remove a bearing cup that fails to press out all the way. Remove bearing cups and driveshaft slip-yoke as follows:

a. Position driveshaft slip-yoke in bearing cup removal tool No. 205-086 or equivalent.

b. Press out bearing cup.

c. Rotate driveshaft slip-yoke 180 degrees.

d. Press on spider to remove remaining bearing cup.

e. Remove driveshaft slip-yoke.

5. Repeat bearing cup removal in this procedure to remove remaining bearing cups and spider from shaft.

6. Clean yoke area at end of shaft.

Assemble

Install the Universal Joint Kits as complete assemblies only. Do not mix components from other kits.

1. Install new spider and bearing cup.

a. Start new bearing cup in shaft yoke.

b. Check needle bearings for correct positioning.

c. Position new spider in shaft yoke.

d. Press bearing cup to just below snap ring groove.

2. Install yellow snap rings supplied in kit to assemble universal joint. If difficulty is encountered with yellow snap rings, install black snap rings. Remove shaft from bearing cup removal tool No 205-086 or equivalent, and install new snap ring.

3. Repeat bearing cup installation in this procedure to install new bearing cup and snap ring on opposite side of shaft yoke.

4. Inspect driveshaft slip-yoke. Install a new yoke, if necessary.

5. Install driveshaft slip-yoke and new bearing cup.

a. Start new bearing cup in driveshaft slip-yoke.

b. Check needle bearings for correct positioning.

c. Position driveshaft slip-yoke on spider.

d. Position assembly in bearing cup removal tool No. 205-086 or equivalent.

e. Press bearing cup to just below snap ring groove.

6. Remove shaft from special tool, and install new snap ring.

7. Repeat slip-yoke installation in this procedure to install new bearing cup and snap ring on opposite side of driveshaft slip-yoke.

8. Check U-joint for freedom of movement. If binding, strike the yoke with a brass or plastic hammer. Do not strike the bearings.

9. Torque front propeller shaft to front axle bolts to 15 ft. lbs.

10. Torque front propeller shaft transfer case pinion flange to driveshaft bolts to 22 ft. lbs.

11. Torque rear propeller shaft to rear axle bolts to 75 ft. lbs.

12. Torque rear propeller shaft to transfer case bolts to 40 ft. lbs.

Single Cardan, Flange Yoke

Disassemble

Do not, under any circumstance, clamp the shaft in the jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing shaft failure during vehicle operation. Place the shaft on a suitable workbench. Do not damage the tube. If components are not marked and installed incorrectly, driveline imbalance can occur.

1. Index-mark the shaft components.

2. Remove and discard all four snap rings.

3. Clamp bearing cup removal tool No. 205-086 or equivalent in a vise.

4. If necessary, use a pair of pliers to remove a bearing cup that fails to press out all the way. Remove bearing cups and driveshaft flange as follows:

a. Position driveshaft flange in bearing cup removal tool No. 205-086 or equivalent.

b. Press out bearing cup.

c. Rotate driveshaft flange 180 degrees.

d. Press on spider to remove remaining bearing cup.

e. Remove driveshaft flange.

5. Repeat bearing cup removal in this procedure to remove remaining bearing cups and spider from shaft.

6. Clean yoke area at end of shaft.

Assemble

Install the Universal Joint Kits as complete assemblies only. Do not mix components from other kits.

1. Install new spider and bearing cup.

a. Start new bearing cup in shaft yoke.

b. Check needle bearings for correct positioning.

c. Position new spider in shaft yoke.

d. Position driveshaft yoke in bearing cup removal tool No. 205-086 or equivalent.

e. Press bearing cup to just below snap ring groove.

2. Repeat to install new bearing cup on opposite side of driveshaft yoke.

3. Inspect driveshaft flange. Install a new flange, if necessary.

4. Install driveshaft flange and new bearing cups.

a. Start new bearing cup in driveshaft flange.

b. Check needle bearings for correct positioning.

c. Position driveshaft flange on spider.

d. Position assembly in bearing cup removal tool No. 205-086 or equivalent.

e. Press bearing cup to just below snap ring groove.

5. Repeat flange installation in this procedure to install new bearing cup on opposite side of driveshaft flange.

6. Install yellow snap rings supplied in kit to assemble universal joint. If difficulty is encountered with yellow snap rings, install black snap rings. Remove shaft from bearing cup removal tool No 205-086 or equivalent, and install four new snap rings.

7. Check U-joint for freedom of movement. If binding, strike the yoke with a brass or plastic hammer. Do not strike the bearings.

8. Torque front propeller shaft to front axle bolts to 15 ft. lbs.

9. Torque front propeller shaft transfer case pinion flange to driveshaft bolts to 22 ft. lbs.

10. Torque rear propeller shaft to rear axle bolts to 75 ft. lbs.

11. Torque rear propeller shaft to transfer case bolts to 40 ft. lbs.

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