Novak Conversions Jeep Wrangler TJ radiator

I found the noise in my front end / axle

TJMexico

TJ Enthusiast
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May 26, 2025
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281
Location
NW Mexico
Last week I posted about a noise from my front end and received some good replies. Grateful for that.

I was finally able to get the Jeep over a pit so that I could maneuver under it and I think that I have found the exact source. Some help here would be useful as I am still just learning.

The Jeep is a 2005 TJ X, all stock.

You can see the action and hear the noise with this video. I will, however, describe what I found.

When I grabbed and wiggled the front drive shaft, it moved just a tiny bit and I could hear a metallic knocking sound. The sound was coming from the passenger side of the axle right near the wheel. When I wiggled the drive shaft, there was very slight movement in the differential that seemed to transferr to the passenger side drive axle. The axle u-joint there did not move, but the noise was definitely seemed to be coming from right there.

Looking closely, I saw that the inner axle shaft oil slinger is loose. (On the driver's side it is fixed.) I have attached a rough drawing below to indicate where the piece is. It looks like it should act as a seal to keep contaminants out of the axle shaft. There is no oil leakage there, but something is definitely knocking around inside.

I have been looking for exploded diagrams of the front axle but have yet to find anything helpful. I would assume that there would be an axle bearing there where the axle comes out of the housing, so I'm thinking that this bearing is shot. Or does the front axle just ride on the wheel bearing? Can anybody give me some solid indication as to what is or is likely happening here?

If so, what kind of pain an I looking at in terms of parts cost, labor time and so forth. I'll head into town in the next few days and either look into doing it myself or finding a competent mechanic.

Also, is this likely something that could cause major sudden catastrophic failure such that I should be careful about driving, or is it more likely something that won't blow up but that just needs to be addressed ASAP?

Many thanks for your help...

LoseSeal.png
 
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That’s just a shield to keep any gear oil that may come out the axle tube from getting on the brakes.

Well, there is no oil on the brakes or the yoke.

So, that would not be the direct cause of the problem?

Any idea, then, where that noise would be coming from or what would be causing it? It definitely seems to be from right there on that side of the axle.
 
The slinger is just a debris shield and it is plastic…I think there is no way it’s causing that sound. I would be looking into the brakes, unit bearing, double check the right axle u-joint, and make sure the axle nut is tight at the unit bearing. Other than that, I’m not really sure what could be causing that noise. Some pinion rotation like that is normal, but that loud metallic clunk is not.
 
The slinger is just a debris shield and it is plastic…I think there is no way it’s causing that sound. I would be looking into the brakes, unit bearing, double check the right axle u-joint, and make sure the axle nut is tight at the unit bearing. Other than that, I’m not really sure what could be causing that noise. Some pinion rotation like that is normal, but that loud metallic clunk is not.

Just had a complete brake job, and there is no movement to transfer to the brakes when I wiggle the drive shaft, so I think I can rule that out. (I initially thought the noise was from the brakes.)

There does not seem to be any play in right axle the u-joint, at least none that I could see. That was what I was thinking recently, but - again - when I wiggle the drive shaft and get the noise, there is no movement in the u-joint. I will look again to see if I just missed it.

If by "unit bearing" you mean the wheel hub bearing, then there is no play in the wheel when you lift it off the ground. It feels solid.

I will look all of those over again to see if I missed something, though. Otherwise, I am stumped. Maybe a stethoscope would be helpful to nail down exactly where it is originating. I will have to see if I can locate one. Or at least a metal bar to press against my temple.
 
Just had a complete brake job, and there is no movement to transfer to the brakes when I wiggle the drive shaft, so I think I can rule that out. (I initially thought the noise was from the brakes.)

There does not seem to be any play in right axle the u-joint, at least none that I could see. That was what I was thinking recently, but - again - when I wiggle the drive shaft and get the noise, there is no movement in the u-joint. I will look again to see if I just missed it.

If by "unit bearing" you mean the wheel hub bearing, then there is no play in the wheel when you lift it off the ground. It feels solid.

I will look all of those over again to see if I missed something, though. Otherwise, I am stumped. Maybe a stethoscope would be helpful to nail down exactly where it is originating. I will have to see if I can locate one. Or at least a metal bar to press against my temple.

Has the front diff been opened lately? I’d open that up and make sure you don’t have a broken side gear on the right side of the carrier. The clank could be that noise carrying down the tube.
 
Has the front diff been opened lately? I’d open that up and make sure you don’t have a broken side gear on the right side of the carrier. The clank could be that noise carrying down the tube.

No, it has not been opened. Something like that crossed my mind. It makes sense, as I didn't see any movement in the end of the axle when I heard the noise.

I´ll have to open it and look. Been along time since opened a diff. I don't have access to fresh bottles of oil here in the village, so I may have to reuse. Or I'll just wait until I get into town. It's about a 90 minute drive.

Question from an idiot: There is no axle bearing inside at the end of the axle tube as the shaft exits and hooks into the u-joint?
 
No, it has not been opened. Something like that crossed my mind. It makes sense, as I didn't see any movement in the end of the axle when I heard the noise.

I´ll have to open it and look. Been along time since opened a diff. I don't have access to fresh bottles of oil here in the village, so I may have to reuse. Or I'll just wait until I get into town. It's about a 90 minute drive.

Question from an idiot: There is no axle bearing inside at the end of the axle tube as the shaft exits and hooks into the u-joint?

No bearing on the shaft. The only attachment points for the entire axle shafts are sliding into the side gear splines at the carrier and the outer stub bolting up in the unit bearing at the steering knuckle. Nothing supporting the middle of the shaft.
 
No bearing on the shaft. The only attachment points for the entire axle shafts are sliding into the side gear splines at the carrier and the outer stub bolting up in the unit bearing at the steering knuckle. Nothing supporting the middle of the shaft.
Then, yeah, something amiss in the diff makes the most sense. I'll try to stethoscope it tomorrow with a piece of rebar, see if I can get a feel for where the noise is originating from.

My main concern now is how dangerous it might be to drive it more. I'm nearly two hours from any place that I could get parts or service.
 
Then, yeah, something amiss in the diff makes the most sense. I'll try to stethoscope it tomorrow with a piece of rebar, see if I can get a feel for where the noise is originating from.

My main concern now is how dangerous it might be to drive it more. I'm nearly two hours from any place that I could get parts or service.

hard to say. Don’t have any other vehicles to drive to go and pick up fluid so you can investigate, and if carnage is found, further drive it some more to pick up parts?
 
My other truck is in the city. I may have some suitable oil in my shop. Will have to see.

Problem is that if it's a bad issue in the diff, I'll need to get it into town anyway. It's been running this way for awhile. Maybe it'll be ok for another trip.
 
Drop the front driveshaft to make sure it's not a u-joint on the shaft. If it is you can drive without the front shaft. Otherwise it is in the differential and is probably carrier bearings that are shot. I'm guessing it's not the pinion bearing as usually that will cause the seal to fail as well. Either way, if it's inside the differential I wouldn't drive it as more damage will result and could eventually catastrophicly fail.
 
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Just had a complete brake job, and there is no movement to transfer to the brakes when I wiggle the drive shaft, so I think I can rule that out. (I initially thought the noise was from the brakes.)

I wouldn't rule out the brakes being the cause.

Occam's Razor...or when you hear hooves think horses not zebras...

-Mac
 
My other truck is in the city. I may have some suitable oil in my shop. Will have to see.

Problem is that if it's a bad issue in the diff, I'll need to get it into town anyway. It's been running this way for awhile. Maybe it'll be ok for another trip.

See this thread for details on how to remove the inner front axle shafts and drive it if you have an issue in the diff.

https://wranglertjforum.com/threads/can-i-temporarily-turn-my-99-tj-into-a-2wd-convertible.84645/
 
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Last week I posted about a noise from my front end and received some good replies. Grateful for that.

I was finally able to get the Jeep over a pit so that I could maneuver under it and I think that I have found the exact source. Some help here would be useful as I am still just learning.

The Jeep is a 2005 TJ X, all stock.

You can see the action and hear the noise with this video. I will, however, describe what I found.

When I grabbed and wiggled the front drive shaft, it moved just a tiny bit and I could hear a metallic knocking sound. The sound was coming from the passenger side of the axle right near the wheel. When I wiggled the drive shaft, there was very slight movement in the differential that seemed to transferr to the passenger side drive axle. The axle u-joint there did not move, but the noise was definitely seemed to be coming from right there.

Looking closely, I saw that the inner axle shaft oil slinger is loose. (On the driver's side it is fixed.) I have attached a rough drawing below to indicate where the piece is. It looks like it should act as a seal to keep contaminants out of the axle shaft. There is no oil leakage there, but something is definitely knocking around inside.

I have been looking for exploded diagrams of the front axle but have yet to find anything helpful. I would assume that there would be an axle bearing there where the axle comes out of the housing, so I'm thinking that this bearing is shot. Or does the front axle just ride on the wheel bearing? Can anybody give me some solid indication as to what is or is likely happening here?

If so, what kind of pain an I looking at in terms of parts cost, labor time and so forth. I'll head into town in the next few days and either look into doing it myself or finding a competent mechanic.

Also, is this likely something that could cause major sudden catastrophic failure such that I should be careful about driving, or is it more likely something that won't blow up but that just needs to be addressed ASAP?

Many thanks for your help...

View attachment 621162

This is not a seal but rather a dust boot. The oil seals are actually in the differential.
 
I had a metallic banging sound from my “right front”. Never could find the source. Followed Blain’s advice from another thread about crawling under and torquing every bolt I could find. Turned out my rear upper control arm bolts were loose at the frame. Tightened them down and no more noise. Could have sworn it was coming from the front. Worth checking out
 
Novak Conversions Jeep Wrangler TJ radiator