I have a 98 Explorer AWD 5.0. It has popping in the front with front drive shaft in. Replaced the drive shaft and it still makes a popping or clunking noise. So I took the drive shaft back out and it stopped making the noise. What could the problem be? Thanks in advance for any help.

SOURCE: 1997 Ford Explorer AWD Problem

awd and 4wd vehicles can't have 2 different size tires run or it will damage the transfer case,but you should be able to get a new bar i beleive what your talking about is called a torsion bar

SOURCE: loud clunking noise when accelerating from a stop

I assume that when you get the noise, the acceleration is compromised, yes?

I would tend to agree with your father. The transfer case chain may be slipping. This is a common characteristic of a "stretched" chain. I would not piddle about with the rear end/differential. If you have a bad diff, the problem would be observed all of the time, regardless of how hard or easy you accelerate. To change the chain, you need to remove the transfer case from the vehicle, remove the outputs from both sides, unbolt and seperate the case halves. The chain is then visible. Just make sure that you do not lose any small bearings, there is a lot of the flat "torrington" type bearings in it.

SOURCE: 1997 ford explorer AWD front drive shaft problem...

Try getting a free quote from several reputable shops before deciding to throw down your money on something your not certain of. Im not dissing your mechanic by any means, it doesnt cost anything to get another opinion or two or three....Its your money!

SOURCE: whining/grinding noise at deceleration

We have the same problem at our shop. We haven't rebuilt the front differential yet. We tried 3 different shafts on 2 different Jeeps and the noise is on both just the same. By greasing the front driveshaft cv joint, we got he noise to quiet some, but it is still way to loud. With the driveshaft out, the noise is gone. We are about to buy a new shaft from the dealer for $600. There are some service bulletins about some noisy driveshafts.

SOURCE: 97 ford explorer awd bad right front cv joint

No, never drive without cv shafts, i tried it and my wheel bearing blew apart and I lost a wheel after driving for 10 miles