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Discussion Starter · #1 · (Edited)
Just finished up doing axle seals on my front Dana 44 and I’m getting a clicking noise when rotating either axle shaft now. I am not getting the noise when I rotate the input shaft. Rotating one axle is make the other side spin, but can be stopped if the other axle shaft is held. Did I break something, is the locker broken, or is something else going on? Using a mirror I double checked to make sure my sensor was in the correct location before closing up the dif cover so that shouldn’t be an issue…
the front and rear will lock up and the lights come on and go off. so does that tells me the switch is in the correct place? Also the front does not click when being rotated by the input shaft via turning the rear wheels in 4lo. I was thinking maybe the bearings are in a bind or something but wouldn’t they still click regardless of what was turning them?
Here is the sound with the dif on my bench : Video
 

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Welcome to ROF, glad to have you here. Is the clicking noise the front or rear axles? If it's the front I would suspect the U joints.
 
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I agree with John, u-joint is the first suspect.
 

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Discussion Starter · #5 ·
Thanks for welcoming me and Sorry my description was incomplete. It’s the front axle and it has brand new spicer u joints, inner axle seals, ball joints and timken unit bearings. I was doing a complete over haul and the axle seals were the last part. The clicking is coming from inside the dif. Could it be that my locker isn’t fully disengaging? If so how do I fix that?
thanks
 

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This ^^ Pull the cover and have a look.
 
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Discussion Starter · #8 ·
What would I be looking for and what can I do to fix it? It wasn’t clicking before the axle seal install. Also would the spider gears only click if I rotated a tire and not click when I rotate the input shaft ? I wish I could attach a video so it makes more sense. Thanks again for the advice
 

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When you rotate the driveshaft the spider gears are not working they don't start doing anything until your front wheels are rotating at different speeds.
Pull your cover and see what is going on.
 
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FWIW, my buddies 06 LJ Rubicon had a clicking sound in the front differential from the day he bought it until the day he sold it. Drove it daily, put thousands of miles on it. Drove it to Moab several times, we did the Rubicon along with many local trail runs with no issues.
 

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Discussion Starter · #11 · (Edited)
FWIW, my buddies 06 LJ Rubicon had a clicking sound in the front differential from the day he bought it until the day he sold it. Drove it daily, put thousands of miles on it. Drove it to Moab several times, we did the Rubicon along with many local trail runs with no issues.
Good to know. I guess I’m just worried because the noise wasn’t there before. I’m going to open up the dif again to see if it’s anything obvious. Was his a ratcheting type sound ?
 

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Discussion Starter · #13 ·
So the ratcheting, clicking noise is in fact my spider gears. They look to be in perfect shape though, is there anything to do about it or is the whole thing shot? Thanks
 

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Is it just me? I don’t have sound on this, iPad or PC.
 

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How many miles are on your Jeep? I’m wondering if your axles and spider gears were behaving until you pulled the axle. I think your spider gears were worn and when you pulled the axles and reinstalled them, your spider gears changed their “happy” place. Seems to me the minimum would be to replace the spider gears. I am no means qualified regarding your issue. I just did some research and I have pulled my axles before. From what I gather, the teeth are not the only part of the spider gears that develop slop from wear. I bet you’ll see plenty of wear on the teeth soon if you leave it as is. If you decide to do only the spider gears, I would at least check the backlash of the ring and pinion since you’re in there.
 

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Discussion Starter · #19 ·
How many miles are on your Jeep? I’m wondering if your axles and spider gears were behaving until you pulled the axle. I think your spider gears were worn and when you pulled the axles and reinstalled them, your spider gears changed their “happy” place. Seems to me the minimum would be to replace the spider gears. I am no means qualified regarding your issue. I just did some research and I have pulled my axles before. From what I gather, the teeth are not the only part of the spider gears that develop slop from wear. I bet you’ll see plenty of wear on the teeth soon if you leave it as is. If you decide to do only the spider gears, I would at least check the backlash of the ring and pinion since you’re in there.
135k on the Jeep. Unfortunately being a rubicon locker the spider gears are not serviceable 😖 I am very frustrated
 

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Let a few weigh in. My conjecture could be wrong.
 
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