Front differential noise

[Weasellee]

Ben’s ‘06 TJR stock front Dana 44 with stock air locker and gearset.
166k miles ish.
His road trip back to Norfolk started hearing a low noise that is now a low speed(15-30mph) then gets quieter due to higher speeds.
Process of elimination noise is a rhythmic thud thud that is coming from the front center of the diff.
Next move is to remove diff cover and inspect but figure id ask if there was an idea o f what it could be.


Also any recommendations for someone to repair in the area if it’s just bearings or a full new carrier and gearset? Not sure its cost effective for me to drive down and do it.


TIA

 

[Blue Clearwater]

If it's determined to not be bearings, could he just pull the carrier, reassemble and drive it back to you?

 

[Weasellee]

If it's determined to not be bearings, could he just pull the carrier, reassemble and drive it back to you?

Hmmm, maybe?

Edit; I don’t think so

Let me clarify I just don’t know if you can drive that way, but I do know that he is capable of doing the job so you tell me.

 

[JKP]

Are you positive it's not the driveshaft?

 

[Weasellee]

Are you positive it's not the driveshaft?

Yes.
Removed shaft from front yoke, jacked up front pass side and spin wheel. With ear it was obvious the noise was from the front center of the dif.
Due to stand down he is working extra so his time is limited and will find an opportunity to pull diff cover and inspect.

 

[JKP]

Be sure to update when you pull cover. Never heard a diff "thud" before.

 

[Cooper Smith]

Be sure to update when you pull cover. Never heard a diff "thud" before.

I knew a guy who, IIRC, got a thud coming from something to do with the pinion gear on a GM 10 bolt. But that was on a Facebook group 3 years ago and I know fuck all about axles...

 

[CharlesHS]

Hard to diagnose without disassembly...
When you drain the differential check the gear lube for sparkly particles.
Inspect the carrier ring gear bolts to ensure there are none missing or loose, pinion and ring gear for cracks.
When you remove the carrier inspect the bearing rollers for scuffing and pitting along with the races for wear marks.
If no signs of problems in the above items; then rotate the pinion listening for rubbing or rough sounds during movement of the pinion.

 

[Weasellee]

Hard to diagnose without disassembly...
When you drain the differential check the gear lube for sparkly particles.
Inspect the carrier ring gear bolts to ensure there are none missing or loose, pinion and ring gear for cracks.
When you remove the carrier inspect the bearing rollers for scuffing and pitting along with the races for wear marks.
If no signs of problems in the above items; then rotate the pinion listening for rubbing or rough sounds during movement of the pinion.

Thank you.

 

[Blue Clearwater]

Hmmm, maybe?

Edit; I don’t think so

Let me clarify I just don’t know if you can drive that way, but I do know that he is capable of doing the job so you tell me.

I'm not 100% sure, TBH. My axle experience is primarily with bigger axles. Dana 60's, mainly. It would work fine with them, but I'm not sure about the 44, having never had one apart. I would think so, but I'm sure someone here would know for sure.

 

[Weasellee]

I'm not 100% sure, TBH. My axle experience is primarily with bigger axles. Dana 60's, mainly. It would work fine with them, but I'm not sure about the 44, having never had one apart. I would think so, but I'm sure someone here would know for sure.

The axle shaft rides in the carrier no? Otherwise it’s resting on the seals?

 

[Blue Clearwater]

The axle shaft rides in the carrier no? Otherwise it’s resting on the seals?

You're right. The axle shafts would be the issue. It would work with a 60 if you took the axle shafts out and capped the hubs or plugged the tubes to keep debris out.

 

[Weasellee]

You're right. The axle shafts would be the issue. It would work with a 60 if you took the axle shafts out and capped the hubs or plugged the tubes to keep debris out.

It would work on the 44 if I drained the diff and just installed outer stub shafts …

Gotta figure out what the problem is first.

 

[Andy-WhiteTJ]

If he is sure the noise is coming from the differential, the best thing to do is take cover off and drain it. Put it on jack stands and rotate the pinion to see what is making noise. I'd also check to make sure the pinion nut is tight and the pinion doesn't move at all other than rotational.

 

[Weasellee]

If he is sure the noise is coming from the differential, the best thing to do is take cover off and drain it. Put it on jack stands and rotate the pinion to see what is making noise. I'd also check to make sure the pinion nut is tight and the pinion doesn't move at all other than rotational.

But is tight and he felt no in/out movement. Will advise when cover comes off.
Andy what you think of driving it with only stub shafts, carrier out and front driveshaft removed? Rags stuffed in end of axle tubes.

 

[Andy-WhiteTJ]

But is tight and he felt no in/out movement. Will advise when cover comes off.
Andy what you think of driving it with only stub shafts, carrier out and front driveshaft removed? Rags stuffed in end of axle tubes.

That would be fine temporarily (a couple of weeks). If the drive shaft and inner axle shafts (keeping the stub shafts installed) are removed, he wouldn't necessarily have to remove the carrier.

Is he coming up here at anytime? We could look at it then.

 

[Weasellee]

That would be fine temporarily (a couple of weeks). If the drive shaft and inner axle shafts (keeping the stub shafts installed) are removed, he wouldn't necessarily have to remove the carrier.

Is he coming up here at anytime? We could look at it then.

That happened on his way back to Norfolk. He won’t get any extended leave for awhile. We gotta see what happens when he takes a peek.

 

[Andy-WhiteTJ]

That happened on his way back to Norfolk. He won’t get any extended leave for awhile. We gotta see what happens when he takes a peek.

Roadtrip!!

 

[Weasellee]

Roadtrip!!

I’m always ready to go. There is a lift on base we can use. I need to bring him his motorcycle soon also I still have a stock complete carrier w locker from the one I bought.

 

[Rickyd]

My front rubi diff has rather loud clicking from the spider gears when one tire is spun. Could it be something like that? If the rubi diff is failing I'd replace it with arb/elocker asap