Clunking noise from front Dana 44 differential

[Jason06]

I started to replace my front axle u-joints this evening because I thought that was the noise I was hearing. When I got it on jack stands and started rotating the axles I noticed the noise was actually coming from the differential. I removed the cover and I am definitely hearing a clunking from the front carrier. Do any of you have an idea what I should look for?

 

[Chris]

Any chance it has a lunchbox locker in it?

 

[Bird]

Could be many things....worn pinion bearings, worn spider gears, loose pinion nut maybe.
All somethings a professional should look at. Imo

 

[jjvw]

This is the noise

Sounds like the locker is partially engaged.

 

[Jason06]

This is the noise

 

[Jason06]

I engaged and disengaged it to check that. If it is partially engaged are there any tricks to get it to disengage?

 

[jjvw]

Can you get it to fully lock?

 

[Jason06]

Yes.

 

[Jason06]

Can you get it to fully lock?

Yes

 

[jjvw]

Has the carrier ever been removed from the housing?

 

[Jason06]

I bought it used so I don’t know if it has. It has 93k on it

 

[jjvw]

The reason I ask is to see if the carrier has been reinstalled with the sensor plunger set incorrectly. This will cause the locker to partially engage.

Does the dash light go solid? Any shavings in the fluid?

 

[Jason06]

The reason I ask is to see if the carrier has been reinstalled with the sensor plunger set incorrectly. This will cause the locker to partially engage.

Does the dash light go solid? Any shavings in the fluid?

The light goes solid. The fluid was still mostly golden clear color. The drain plug had some build up on it but nothing different from what I have seen on other vehicles

 

[1945GPW]

I think I had the same issue with my front end. It had this tank track sound mostly in 4 wheel drive and under a load, I took the front drive shaft off, jacked the tires up and could still faintly heat it in the housing area. I did some inspections of my own and couldn’t find a problem, so I took it to a shop and had them tear into the axle. They checked everything. U joints, bearings, locker, gears and couldn’t find anything wrong. The Jeep has 90k miles on it as well and they said everything looked new. They mentioned that maybe a slightly heavier gear oil would take the noise away. They used 80w90 and so far I haven’t been able to duplicate the noise.

I don’t know if they changed something unknowingly when putting it back together or if the gear oil was the trick but I’d try changing the gear oil first and hopefully you can save 430 bucks unlike me lol

 

[Jason06]

I think I had the same issue with my front end. It had this tank track sound mostly in 4 wheel drive and under a load, I took the front drive shaft off, jacked the tires up and could still faintly heat it in the housing area. I did some inspections of my own and couldn’t find a problem, so I took it to a shop and had them tear into the axle. They checked everything. U joints, bearings, locker, gears and couldn’t find anything wrong. The Jeep has 90k miles on it as well and they said everything looked new. They mentioned that maybe a slightly heavier gear oil would take the noise away. They used 80w90 and so far I haven’t been able to duplicate the noise.

I don’t know if they changed something unknowingly when putting it back together or if the gear oil was the trick but I’d try changing the gear oil first and hopefully you can save 430 bucks unlike me lol

Thanks for the info, i’m going to get back to work on it tomorrow to see if I can figure it out

 

[jjvw]

I wonder if we are hearing the spider gears.

 

[Jason06]

I wonder if we are hearing the spider gears.

If it is the spider gears are they hard to change?

 

[jjvw]

If it is the spider gears are they hard to change?

Probably not. The issue is finding a set other than from a used locker.

 

[Boinked]

@Jason06
That looks like a factory air locker.

If this is the case there is no spider gear.

I don't know enough about the factory lockers to say if its a problem.

I would take it to an expert. They might be able to rebuild or you might have to replace it.

 

[jjvw]

@Jason06
That looks like a factory air locker.

If this is the case there is no spider gear.
View attachment 64615

I don't know enough about the factory lockers to say if its a problem.

I would take it to an expert. They might be able to rebuild or you might have to replace it.

That is the rear with it's gear driven LSD. Jason is talking about the front locker which is open and uses a single pair of spiders.

Unfortunately, our lockers are not rebuildable due to a lack of available parts.