Just had the rear diff rebuilt nad I don't think the mecganic replaced evrything he said he did. Still here a bump sound when starting from stop, and there's about 1.5 inches of play in the rear end. (I can turn one of the rear wheel 1.5 inches or so before other wheel turns)
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problem most likely not in the diff but in the diff mounting and suspension points
a noise on acceleration or deceleration indicates that the diff housing is free to react to the load being applied and that is mounting bushes , broken mounting plates or other suspension problems
consider this to see if it fits
when you accelerate the reaction of the diff is to roll upwards as the wheels have traction but when under brakes ( deceleration ) the diff rolls forward
hence the bangs in both directions
suggest that you change mechanics and take it to a specialist shop that deals in your make of vehicle for a proper under body inspection of mounts , rubbers, pins and chassis mounting points
another issue her and that si the engine reacts the same way so check engine mounts and reaction rod bushes
ask diff reconditioners shop or off road shop if a limited slip diff center is available ( welding diff centers is not an option as it makes the car illegal on the road and dangerous to handle on a good road surface )
you need tall gears that do not loose traction because of the torque advantage from low ratios as in the switch on the dash. so don't use it in tow mode
as for tires there are special snow tires available with spikes in the tread , special tread patterns
( ask a tyre shop for what would be best)
extra weight over the rear end would help with traction
I would think that wide tires would tend to "aqua plane" as they rode up over the snow but talk with a tyre shop again on that
there may be a diff locker available from an off road shop
Consider changing the entire rear end to get the diff operation that would best suit you
check the "u" joints and check that the drive shaft flanges have been properly fitted to the pinion flange or that the "u"joints have been properly fitted into the pinion "ears " of the pinion.. Check that the correct grade of oil was used in the diff and it has the correct amount. New out of the factory diff should not be noisy but if you have a new rebuilt diff then it is possible that the gear mesh is not correct or used gears were used where the best mesh was obtained.
I had a 4x4 year ago. Do you have front locking hubs ? I don't think so if you did I would ask if they were in or out. If there is nothing else It has to be coming from the transfer case. As far as I know no manufacture makes a true 4 wheel drive but Jeep except for maybe Raptor or Power Wagon. Most come with an open diff in the rear one wheel drive unless you order it special and the front you can't even order a locker if you wanted to 99.+% of 4x4s have open diffs in the front. Jack up one front wheel and one rear wheel if you didn't order a special rear end if you try to drive off the jacks you will sit there and spin your 2 wheel drive and not move.Ford says if you have worn tires or not the same air pressure in all tires it will do this. I think you have a bad u joint or pieces broken in the transfer case or it is out of adjustment. Jack car up like I said before and when the wheels spin without pulling it off the jack stands crawl under and see where the noise is coming from front or transfer case.I wonder if your shift motor could be bad they are about 65 dollars
You should be able to buy a good used one from a junk yard for half what the parts will cost to fix yours. To rebuild rear ends you need all kinds of special tools to set the end play and run out. It is not that hard of a job to replace the whole thing either. Especially if you have four wheel disc. spray up all the bolts and the brake lines with penetrate the day before you start.
Hope this helps
Just a note, I owned and independent trans shop, an AAMCO and manage sever trans shops over the years and in all that time I don't think we rebuilt more than one or two rears. However we replace many.
it is a 2007 vehicle so there would be no warranty on the diff
as for the cost , replacement diffs from wreckers. junk yards with the same ratio would be less that 1/2 that so I think that you are being touched in the wallet area or get a fully rebuilt diff from an accredited diff and transmission specialist shop
well don , if this is a 4wd , actually even if it wasn't i show it to have locking diff(s) , if you have 4wd i show you to have a switch and a light somewhere on dash display indicating if it is locked in or not . , if you look at the passenger side of the rear differential you might see some electronical gizmo attached to it . i recently worked on a lx470 , it was awesome , i cracked the woodgrain cover around the power window switch , ouch , it cost $500 just for that little piece of woodgrain , lexus is very proud of their parts , lol , enjoy that vehicle . i would sure appreciate a FIX YA vote . thank you .