I have a 96ford explorer XLT AWD with the front drive shaft off should i be able to turn the front output coupler all the way around or does that mean something is broken inside?

noise in front of 98 awd explorer - Ford Truck Enthusiasts Forums

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Jul 1, 2011 - noise in front of 98 awd explorer Explorer, Sport Trac, Mountaineer & Aviator. '98 Explorer Loud DriveTrain Noise
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awd will be working all the time and is not accessible or changeable. The 4wd bit comes into play when 4wd is selected at the switch or lever and if locks the Centre diff (awd diff) to make both front and drive shafts turn as one.
Check with a workshop manual to see how it works and where the problem may be.

No 4X4 switch on the instrument panel ?
Automatic Transfer Case
The single speed automatic transfer case system shifts automatically from rear wheel drive to four wheel drive when the transfer case shift control module (TCSCM) senses the difference in rotation speed of the front propeller shaft and the rear propeller shaft . Two vehicle speed sensors, one located at the rear output shaft area of the transfer case, and the other, located at the front output shaft area of the transfer case, send front and rear propeller shaft rotation speed information to the TCSCM.
When the front and rear output shaft rotations remain the same, the TCSCM sends pulse width modulation signals to the encoder/motor to keep the transfer case in rear wheel drive. When the front and rear output shafts rotations are different, the shift control module sends pulse width modulation signals to the encoder/motor to engage the transfer case into four wheel drive.
The system will automatically transfer a percentage of torque to either the front or rear axles as required to stop all wheel slip. When the front and rear output shafts rotations return to the same speed rotation, the shift control module sends pulse width modulation signals to the encoder/motor to position the transfer case back into rear wheel drive.
When the transfer case is engaged into four wheel drive, a lamp indicator on the instrument cluster will light. The automatic transfer case system is completely automated, no transfer case control button switching system is required.

Do you know what DTC'S - diagnostic trouble code's are ?
Auto part stores can't read these , your best bet take it to a qualified repair shop . One that has the knowledge an diagnostic equipment .
DTC C0300 Rear Speed Sensor Malfunction
DTC C0305 Front Speed Sensor Malfunction
DTC C0308 Motor A/B Circuit Low
DTC C0309 Motor A/B Circuit High
DTC C0310 Motor A/B Circuit Open
DTC C0315 Motor Ground Circuit Open
DTC C0374 General System Malfunction
DTC C0376 Front/Rear Shaft Speed Mismatch
DTC C0550 ECU Malfunction
DTC C0611 VIN Information Error
DTC C0895 Device Voltage Malfunction
Without proper factory service an repair info. an diagnostic tools

Bad Steering Rack--about all that is left or it is
loose on it's mounts

I see AWD. That is a whole new senerio

The backing up part would point to Axle CV Joints
in the front

The AWD Transfer Clutches are a subject of another day
The correct oil in there also,hope your not going there for
any reason

Check out all drive shaft joints,even if not related

Can not just drive a 4x4 without laying it up about a week
every year & going thru it looking for trouble,that is what I
do with all my vehicles,weeks if necessary,I never wait for
anything to happen ,I look for trouble

I would pull the transfer case
Strip it & replace what is needed
& go from there, after reinstall

I would never install a used part
until it stripped it.

DONT DRIVE WITH OUT DRIVE SHAFT. JUST REPLACE THE UNIVERSAL JOINT BEARINGS ON DRIVE SHAFT.

Struts

Yes you can, If you have taken the front drive shaft off, you can even still drive with the CV joint in place till you want to remove it. You may get some vibration around corners till you replace the CV joint or remove it totally.
But if your going to remove it, might as well wait till you have the replacement so you only do the job once. I had a Bad CV joint on a AWD Chevy van and did the same thing so i could still use it, and then replaced the CV joint when the weather got better.
Good luck and hope this helps.

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!

If the vehicle is made to be a AWD you cannot get it out of AWD unless you take off the front drive shaft