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This has been going on for a while. metal on metal only when the front diff is engaged, so I know it's not the wheel bearings at least. It's the loudest under deceleration. I pulled both hubs thinking it was perhaps a spindle bearing or something, but they're both good. repacked everything, changed a couple seals and reassembled. Checked the pinion bearing and just for kicks, the front bearing on the transfer case. All nice and tight. No filings or signs of wear in the diff itself when I had the cover off to change the oil. Pulled the drivers side half shaft and saw no signs of wear at all. I hadn't checked the carrier bearings, but you'd think there'd be significant wear on the gears and filings in the oil.
Suggestions?
I jacked the truck up and ran it in various gears and configurations. Thought I heard something in the rear driveshaft. Replaced the front joint in the rear shaft and the rear joint in the front shaft ( cheap insurance) No change. I did notice that the noise isn't there unless the hubs are locked. I can run it with the transfer case engaged and no noise, but with the hubs locked,the noise is there whether or not the transfer case is engaged.
Ideas?
X2 on the U-Joints, mine made the God-Awfullest noise when I was moving in 4wd. My U-joints were shot. Changed them and converted the Auto Hubs to Lock-ins. Problem Solved!
It could also be the self centering yoke assembly in the double cardon joint on the front drive shaft. Mine was bad when I git the truck and it made more of a squeaking noise than a grind, but it was the same story, I only heard it when I had the front hubs locked in. There is a little needle bearing in there that can go bad. Here is a link to the writeup with pictures. Good luck finding your noise!
My front shaft only has 2 joints. It came that way on the donor truck. The parts guys always say "well, that's what the picture says" Sorry, that's not what the truck has. Anyway, thanks. I haven't changed the axle joints. Kinda spendy. NAPA wants $82 each. I know it'll be worth doing, just trying to find the ambition to tear into her again.....
assuming you have the dana 50 still, i got mine for 12$ each LOL given thats a discount at carquest but we all know there mark up is horrendous, i beat the crap out of them and they were still good. dana 50 ujoints are dirt cheap but dana60 are VERY spendy. im having the exact same noise in my truck with the dana 60 conversion, at 70+ per joint i hardly find the motivation to do them since they were tight.
Dana 60 in mine. I do get a discount there and I didn't ask what the difference would be using it, so it may be a little better. I'll have to check it out. It's really unpleasant, ain't it?