[BobsLJ]

Highly unlikely that the clicking sound started after your reseal. It had probably been that way for awhile and you just didn’t notice it.
At 135k miles there is bound to be a little wear on things. Just because it’s worn a little doesn’t mean it’s bad.
My opinion only. If it were mine I’d put it back in and run it until it breaks and then replace it with an ARB or Elocker.
Going to 90 weight gear lube may quiet the noise some.

 

[Norminator]

Not to be a negative guy or anything, but that grinding is pretty dang significant.

 

[OctaviousMonk]

Not to be a negative guy or anything, but that grinding is pretty dang significant.

And that’s why I’m here looking for ideas. As anyone fixed anything like this in a tj rubicon locker? Could it be a shim or adjustment issue?

 

[Norminator]

When I was researching worn spider gears I came across the "BS"Korner guy that talked about his spider gears and knocking out a pin to get them out. I didn't mention it because you seemed to think the Rubicon locker wasn't serviceable. One discussion on the web mentioned difficult parts availability.

 

[Norminator]

I revisited your first posting and we’ve all learned quite a bit about your source of noise. I can hear your frustration in your replies. You did much by providing a bench video. Now you or someone is going to have to narrow it further by looking deeper inside. I personally wouldn’t rebuild my own differential, transmission, or engine. I have a 2004 FSM and couldn’t find anything specific about getting to the spider gears.

I myself would put it back together and take it to a shop. There aren’t very many shops that want to help a DIY get over a hump, although I have met one or two mechanics that did help in that way. At least you know more having put hands on.

 

[OctaviousMonk]

Thanks

 

[Al_S]

I've had a faint spider gear noise in my front diff as long as I can remember. You'll have to think about what your long term plans are for the Jeep. Are you happy with the gear ratio? This could be a good time to replace the OEM locker with a more robust ARB air locker or Eaton E-locker. I'd say you could put it back together and drive it while you budget and gather parts for a permanent fix.

I have an ARB in the rear of my 04 and the OEM in front. If I have any issues with the front I'll get another ARB installed. I haven't been very impressed with the stock lockers on the TJ Rubicons, I guess that's why Jeep went with electric in 07.

 

[heck]

imgur is blocked for me at work, so I didn't watch the video. On my 03 with air locker, if the lock indicator switch isn't perfectly happy, it holds the locker partially engaged. Stupid design, but it was teh Daimler years.

 

[OctaviousMonk]

imgur is blocked for me at work, so I didn't watch the video. On my 03 with air locker, if the lock indicator switch isn't perfectly happy, it holds the locker partially engaged. Stupid design, but it was teh Daimler years.

And what was the fix, a new switch?

 

[heck]

On mine, the switch is a plunger with a large flat head like a large short nail. Unless there's some magical trick I never learned, you have to install the switch with the carrier removed. As in disassembled (**** Daimler). Putting it in after pushed the locker to engage.

 

[heck]

The censored word starts with a capital F.

 

[heck]

Anyway, might be causing partial locker engagement.

 

[johncanfield]

The censored word starts with a capital F.

Let's Go Daimler!

 

[Beowulf]

Any update on this? I just started getting this type of noise in the front.

 

[johncanfield]

I haven't read through this thread but clicking in the front is sometimes an axle U joint.

 

[Beowulf]

Sadly I have RCV, or that would have been my first checked item

 

[Norminator]

I was investigating ticking from an axle once and found an aluminum button looking thing on my tire. It turned out to be a screen door handle.

 

[johncanfield]

Same basic thing happened to me. I forgot what vehicle it was but a small rock was caught in the wheel area making a clicking noise.

 

[Mouse]

I've seen RCV's start to wear out and make sound. It was sort of a click, but not like a u-joint