Ford Transmission :: 4R100 - 2000 Ford Excursion - Grinding / Vibration Occurs Between 2100 - 2300 RPMs


Sep 14, 2016

I have recently found what sounds like a grinding/vibration issue that occurs between ~2100-~2300 RPM's in my truck. After some googling, I thought it may be the inspection plate being a bit bent/loose. I took the cover off and drove around and the noise still occurred.

Things I have noticed:

-Occurs between 1-2 and 2-3 (had trouble with the other gear changeovers as I just have slow backroads around me to test over my lunch break- can test further in the future)
-Occurs during acceleration and deceleration
-Starts at ~2100 and ends ~2300 RPM

Any thoughts for next steps to diagnose? Truck has ~160k on it and I don't really have many service records (purchased within the past 3k miles and problem just started occurring after this past weekend). Transmission fluid seems to be in decent condition.

Not sure if it would affect anything, but I just got back from my first trip with the Excursion where I actually needed to utilize the 4WD. There was much more aggressive terrain than what it is used to seeing on the pavement. Thought I should mention that as well.

V10, if that matters (I recall reading somewhere that '99 7.3s with the auto had documented torque converter issues that warranted a TSB)....

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Removed the rear bolts and dropped the rear of the shaft. Cut off the factory boot clamps. Marked the shaft so it could go back in the EXACT way it came out and removed the rear of the shaft with the boot intact. While the rear of the shaft was out I checked the joints and found them to be perfect.

There was no real grease to speak of left, just the factory ford blue. Filled it and the splines with moly grease and re-installed the shaft and boot. Clamped the boot with nylon ties (per his suggestion). No vibration any longer. Thought I would post this up as a quick tip.

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Replaced wheels and tires (I bought new ones for my f350 and put the ones that came off the f350 on the excursion, so I know they were balanced and smooth)
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Through all these changes, the vibration has changed by degree but never gone away completely. Today, I had a bit of a revelation, and would like any input.

It has come to my attention that some excursions were given a double cardan rear driveshaft, mine included, and some had what I would call a standard driveshaft (one ujoint on each end). From what I know, with a standard driveshaft, the pinion should be angled parallel to the transfer case output shaft. However, on a double cardan driveshaft, the pinion should be angled "in-line" with the driveshaft. I measured mine with a digital level and the pinion is angled parallel to the transfer case output shaft.

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