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Front end episodic noise and clunking

5K views 32 replies 10 participants last post by  johncanfield 
#1 ·
I need help diagnosing some issues I am having in the front end of my Jeep.

Issue: Front end binding and clunking noise that is coming from the front end. It sounds like its in the drive train... maybe axel u-joints. The noise goes away after I drive it forward and repeatedly press the brakes.

Conditions: The condition happens after the Jeep has been allowed to sit a few days. I am usually able to resolve the issue by pressing on the brakes and it eventually goes away (its taking me longer and longer each time to get it go to away).

Steering does not appear to be a factor - steering does not cause the noise or help resolve the issue. The noise is manifested regardless of if I take off straight or turn the wheels. It also does not help resolve the issue if I turn the wheels.

Transfer case is not a factor - The position of the transfer case 4hi or 4low do not cause or help resolve the issue.

I think the issue maybe in the front axel it self, however, that doesn’t explain why pressing the brakes get it to go away. I have completed a visual inspection of the front end, U-joints, Hubs, etc. and nothing obvious sticks out.
 
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#2 ·
Glad to have you in the forum.

My buddy had front end clunking. We had just finished a trail and were in a parking lot trying to cause “this” to figure “that.” His seemed torque related. Finally I grabbed the u-joint where the front driveshaft connects to the transfer case and man handled it. I could feel the slop and actually produced a clunk. That was indeed his problem. It’s probably one of the few times we felt like winners discovering a problem.
 
#3 ·
Unfortunately sometimes with issues like this it is hard to pin point and even harder to make the noise yourself by grabbing and shaking or twisting etc.... Many times if you can do that and get things to make the noise you have to really give it hell like Norminator alluded to. In my case with some front end issues, I had to remove and inspect parts piece by piece. I had a noise once and it wasn't until I had the axle out of the front on one side that I could easily tell it was a ball joint. Depending on the amount of miles on the jeep, sometimes doing things like that provides a good opportunity for some general maintenance "since you are in there anyway".
 
#5 ·
Thanks everyone for the input. I have done some more testings and think it is something in the front diff. I lifted the jeep off the ground and put it in 4WD to see if I could replicate the noise and I did. I also check the diff fluid and it is coming out of the eyelet so no issues there.

The drivers front driveshaft is making the clanking noise as the drivers front wheel moves. When I stop the drivers front wheel (by hand) to allow the passenger tire to spin freely the noise goes away. What could this be?

Linked is a video to me spinning the passenger wheel by hand and the associated noise. I think this is the point I probably take the Jeep into the shop. I can replace a wheel hub and u-joint…but I feel opening the diff and trying to figure that out. Is that probably the best route?

Link to video:
https://youtu.be/mmXrZm6u6EQ
 
#6 ·
As rapid as that clicking sound is, I would guess it is the wheel bearing.
 
#9 ·
Alrighty,

I think I have discovered the cause of the noise. I removed both front hubs and axels and the hubs and u-joints are not the culprit. They operate just fine. Afterwards I opened up the front differential and can now see where the noise is coming from. Side note, upon draining the differential I found a decent amount of material on the magnetic plug at the bottom of the axel. I found the noise in the axel housing (I think this is what it is called). The metal looks a bit deteriorated. This is where the noise is coming from. Maybe it is the spider gears? I am not too familiar with working on differentials. Is it best just to replace the whole housing unit? Or should I try to take apart the whole assembly? Hitting the pause button on this until I can figure out how to tear this thing down and move forward. Any advice moving forward?
 

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#11 ·
From the little searching I have done... it looks like I need to get a whole new locker because the factory ones are not serviceable. I’m finding out you can’t just buy one of these new as they don’t make them anymore. Pending the advice I get on here I may look around at local junk yards for the part.
 
#14 ·
You are correct in that the locker is not serviceable. And the front one is usually not the one that causes issues. From what I have seen, you can get a new front OEM locker, but the price is to the point that it makes no sense when you could go with ARB for the same or not much more. The only positive thing about using a new or even used oem locker is you MIGHT be able to swap it all over yourself and be fairly set and ready to go. VS a new setup where backlash and preload will have to be set. The Yukon lockers have a good reputation in my area also, but ARB is always king. Depending on what you decide... do not rule out simply buying a new axle assembly. It might be just as cheap or cheaper if you wish to stay OEM to find a whole front someone is selling and you can swap out.
 
#15 ·
Depending on what you decide... do not rule out simply buying a new axle assembly. It might be just as cheap or cheaper if you wish to stay OEM to find a whole front someone is selling and you can swap out.
Good suggestion.
I might add to look close by due to shipping costs, but more importantly...
if you're in CA the sight of an axle from the NE might cause a myocardial infarction. :surprise:
 
#16 ·
Update

Thanks for the advice. I took the carrier out to inspect it this morning and found a pin slightly out that I could not put back in. I put the small drive shaft in the differential and spun it and feels like a lot of binding and resistance and noise. The bearings looked and felt good. There was noise and resistance coming from the locker acutuator as well but this was small compared to the rest of the carrier. There didnt appear to be anything obvious that I could fix. Anything else I should trouble shoot or try to fix on this? Looks like im in the market for either a used carrier/locker or a used axle. I may just leave the carrier out and put the jeep back together in the mean time. I prefer to use the OEM locker to keep it all stock.
 

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#18 · (Edited)
Figured I would post an update. I ended up getting a used OEM locker. Just finished installing the locker. I figured I would make a day of it and replaced the ball joints, u-joints, and hubs as well. So far so good. Locker fully works. It does take a little while for both lockers to engage but that’s an issue for another day. Thanks all for the help.
 
#21 ·
If you can still make it happen on the jack stands then start taking it apart.
Your video sounded external to me. A sharp noise, not muffled like inside the housing.
Driveshaft off, still there? Take the wheels off try again, take the calipers and rotors off, still there?
 
#22 ·
Update



The Jeep is fully assembled right now. I am baffled because before I replaced the ball joints, u-joints, and Hubs I drove the Jeep for a bit with just the small drive shafts and took the inners out. While waiting for the parts to arrive... I experienced the same binding motion and noise (it’s enough to cause the Jeep to move differently). You would think it is in the drive train by the way it acts, however, the issue happened even when the axle shafts were out so that is the confusing part. Nonetheless, I can temporarily fix the issue if I pressed the brakes. At this point I was thinking it was the hub for sure... so I replaced all the parts a few days ago and thought it was fine, however, it is not. Its come from the passenger front. I have replaced all the major parts in the area. I am wondering if it may be the brakes. I am letting the Jeep sit for two days and I am going to mount a camera on the front to see if I can record what is going on. I have thought about putting it on jack stands again as well. The weird part is the issue pops up only after the Jeep sits a day or two. If I regularly drive it... doesn’t really become an issue. I thought about letting it sit two days (to get the issue to happen) and then just driving it to the point of part failure instead of pressing the brakes. I am ready to know what the issue is so I can fix it and call it a day. I’ll follow up after I make the video.
 
#26 ·
It’s more of a binding sound. It doesn’t sound like the video I posted. I’m thinking this problem is a conglomeration of several problems... which I have fix some of them. I believe I have fixed the noise that is shown in the video with the replacement of the locker. I have not tried removing the caliper yet. However if it persist I will. See below.

..... I am wondering if it may be the brakes. I am letting the Jeep sit for two days and I am going to mount a camera on the front to see if I can record what is going on. ....
As I was reading I immediately thought about brakes, then you mentioned it. I know some here have reported dragging calipers/pads - you might look over those threads for similarities to your issue.
Thanks. I will look more into it... In fact that may be it. So I just fired up the jeep after letting it sit a few days and it drove normally with no issues. Of course the video was rolling so maybe I am just not lucky enough to catch it. Before I parked the jeep a few days ago I cleaned the metal surface the brake pads slide along because it was very dirty and gunky. It has yet to make the noise since two days have past since cleaning it. I’m hoping that’s it. Time will tell and I’ll keep posted.
 
#27 ·
Well. Jeep is still making the noise as of the morning. Normally it has to sit a few days. However, it ended up making the noise the morning. I managed to get a short video (link below). After holding the brakes and driving a few feet the noise cleared up. I am going to try pulling the rotor and caliper from the passenger front to further trouble shoot.

The video:

https://youtu.be/sX8u46AtP4c
 
#28 ·
Sure sounds like Gear noise. Did you replace your ring and pinion when you changed your 3rd member?
If you disconnect your front drive shaft does the noise go away!
How about if you turn it by hand?
You might also check your unit bearings.

FWIW, my buddy had an 06 LJR with the exact same front diff noise. We never did figure out what it was, but he made 3 trips to Moab and ran the Rubicon along with numerous local trails with no issues and it still clacked when he sold it.
 
#29 ·
Alright. I may have found out what the issue is. I got feed up and took the jeep to a driveline specialist to have them diagnose it because I had hit a wall. After a week or so of research and diagnosis on their end they are convinced it is the brake pads, specifically the friction of the pad against the caliper. If you remember, I removed the passenger front caliper to try to rule that possibility out. However, I did not isolate the drivers front caliper (shame on me). Nonetheless, upon their research they have discovered that around this model year it is necessary to put shims on the front brake pads. Apparently this is a known problem around this year model. Attached is the picture of the really expensive shims that will hopefully fix the issue. I say really expensive due to the total cost of the hubs, u-joints, etc. At least I have a new front end now! So far the jeep is driving great and no issues. Hopefully, in a few days I can confirm this!
 

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#32 ·
Well I think we can finally close the case on this one. After a week or so of driving with no issues... the culprit was the brake pads. Adding shims to them has stopped the issue. Hopefully the thread will help the guy or gal who suffers the same ailment in the years to come. Thanks to everyone who has offered help and advice!
 
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