2002 Ford Explorer klunk, klunk, klunk

GROGND

MEMBER
2002 FORD EXPLORER
6 CYL
4WD
AUTOMATIC
95,000 MILES

I just picked up our Explorer from the dealer for the second time this month. They said that they have checked the front end and found no suspension problems. They have changed the transmission, steering, and differential fluids.

I explained that there is a klunking sound that seems to come from the front of the car. This sound only happens when I first start the Explorer after it has been sitting for 2+ hours. The klunk kllunk klunk and a very slight mechanical whining occurs in forward or reverse when turning. I tried rolling out of my driveway with the engine on but the transmission in neutral this morning. Same sound. My driveway has about a 20 degree angle and my Explorer should have rolled well into the street. However, the klunk klunk klunk. Whine. Happened and the Explorere stopped at the base of the driveway! All of this with the Explorere in neutral!

Any ideas? I've given up on the dealer.

5 Replies

KHLOW2008

MECHANIC
41,815 POSTS

Hi grognd,

Thank you for the donation.

Does the noise appears only when the vehicle is in motion and the steering is turned? Left or right or either side? Does it go away after the engine has been warmed up or when vehicle speed is increased?

Front brakes had been checked? 4 x 4 system checked?

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Friday, August 1st, 2008 AT 4:35 PM

GROGND

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5 POSTS

The noise happens when the Explorer is in motion. The noise doesn't happen when I'm driving straight - forward or reverse. Only when the wheel is turned to the right or to the left.

I did recently have a brake job done on all four wheels. However, I was hearing the same noise before I had the brake job done.

I didn't have the four wheel drive checked. What is done to check the four wheel drive?

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Friday, August 1st, 2008 AT 9:26 PM

GROGND

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Oh, and the noise only happens when the engine is not warmed up.

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Friday, August 1st, 2008 AT 9:32 PM

KHLOW2008

MECHANIC
41,815 POSTS

Hi grognd,

Is the engine rpm high during cold start? How long does it take to go down to normal idling speed? What is the idling speed?

If the noise disappears after the engine warms up, I believe it should be something to do with the engine rather than others.

I suspect it should be something to do with the exhaust, heat shields, catalytic converter or engine mounts.

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Friday, August 1st, 2008 AT 11:01 PM

GROGND

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5 POSTS

Cold start rpm is approx 12000 for about 1-2 minutes. Normal warmed up rpm is approx 7-9000 rpm.

I get more of the klunk and vibration from the front end in the morning when the engine is cold.

Yesterday afternoon, there was no klunk or vibration when starting engine cold. But, my explorer had been sitting in the sun for a few hours.

I still only getting the klunk and some vibration when turning. Never when driving straight.

Does any of this make sense? Seems odd to me.