Re: Bronco Clunks and rattles
The Ford 8.8" rear ends are famous for axle end play and "clunking" when putting the tranny in gear. The clunk is usually just the combined play in the tranny, transfer case, and rear end. As long as there's not excessive backlash in the rear end, the tranny mount is ok, and the u-joints are fine, there's nothing to worry about.
It cost me $800 in parts for the ring, pinion, posi, spyders, shim kit, carrier bearings, and an install kit for a new rear end when I blew mine a year or so ago and haven't had any "clunking" issues since.
The noise you're hearing when going over mild bumps is most likely due to the axle end play. Jack your vehicle up and remove the wheel and drum on one side. Grab the axle flange and move it in and out. You'll feel the end play. All of the driveline shops I've talked to in the past say it's nothing to worry about but I agree it is a little irritating.
The radius arm bushings on the front end on the later model Bronco's with the Dana 44 IFS also go out, causing a clunking noise when going over bumps. It's easy to change in a couple of hours and will tighten things up.
1992 Ford Bronco
E4OD- B&M Stage 2 shift kit
Full 3" stainless Bassani Exhaust
32" BFG's/stock suspension
"No replacement for displacement."
"Our lugnuts require more torque than most Honda's produce!"