Dirt grinding noise from front driveshaft / transfer case

Bowhunter · May 31, 2020

Attached is a video of me hand turning the drivers side front wheel while it’s in the air. The noise seems loud in the video buts it’s just barely noticeable while driving (I can barely hear it while the engine is at idle and I’m coasting with no acceleration)

Almost sounds like there is dirt somewhere that is being crunched. Can’t tell exactly where it’s coming from but I think it’s either the drive line, u joints or transfer case. I don’t hear it coming from the differential. It makes the dirt crunching noise in two specific locations during the rotation of the drive line.

What’s your thoughts?

Chris · May 31, 2020

Dirt? That sounds like metal on metal to me. Have you checked the u-joints?

Bowhunter · May 31, 2020

Chris said:
Dirt? That sounds like metal on metal to me. Have you checked the u-joints?

It’s difficult to explain.. to me when I was hearing the sound in person it sounded like dirt or very small rocks crunching in between pieces of metal. But maybe it is metal crunching between metal.

The u joints near the front differential seem to be good and not making the noise. The stock skid plate blocks the u joints near the transfer case. I’ll take the skid off and take a look at the u joints by the transfer case. As of now I’m not experiencing any shakes or wobbles at speed, just some noise

Daryl · May 31, 2020

Remove the driveshaft and check the joints for free smooth movement.

eastbloc · May 31, 2020

that is a sound of metal on metal

Sancho · Jun 1, 2020

Brake shield too close to rotor?

Goatman · Jun 1, 2020

Wheel bearing? Have you checked that all your drivetrain fluid levels are full and clean fluid? But I'll go with a ujoint if it's only in 2 spots during rotation (if they are 6 hours apart (happens when tire is at 2 and 8, 5 and 11, etc)
On a 'smart phone's that didn't play your file.

Bowhunter · Jun 1, 2020

Sancho said:
Brake shield too close to rotor?

Good idea but I checked that yesterday and the noise seemed to be coming from the front drive shaft U joints or transfer case

Bowhunter · Jun 1, 2020

Goatman said:
Wheel bearing? Have you checked that all your drivetrain fluid levels are full and clean fluid? But I'll go with a ujoint if it's only in 2 spots during rotation (if they are 6 hours apart (happens when tire is at 2 and 8, 5 and 11, etc)
On a 'smart phone's that didn't play your file.

When I had the drivers side wheel in the air and rotating the wheel, the noise wasn’t coming from the hub/whee area, but good idea and thanks!

It was mainly making the noise when the drive line was at about 12 o’clock and 6 o’clock, 180 degrees apart

I’m going to take off the skid plate today and take the front drive line out and inspect the U joints. I will also check the fluid level on the front diff and transfer case. Will follow back up later tonight with what I find

Vinman · Jun 1, 2020

Before you remove the skid plate try disconnecting the driveshaft at the pinion then rotate the tires again. That will either confirm or rule out the front axle assembly as the source of the noise.
If it were mine I would do the diagnostic in the following order:
1- disconnect the shaft at the axle end only as stated above
2- rotate tire, if noise is still present check wheel bearings and ensure no debris caught between backing plate and rotor
3- if rotating tire does not produce the noise spin the driveshaft while still disconnected from the axle
4- if noise is present remove front driveshaft for thorough inspection and while its out, rotate the front flange on transfer case to ensure noise is not from the t-case

Bowhunter · Jun 1, 2020

Vinman said:
Before you remove the skid plate try disconnecting the driveshaft at the pinion then rotate the tires again. That will either confirm or rule out the front axle assembly as the source of the noise.
If it were mine I would do the diagnostic in the following order:
1- disconnect the shaft at the axle end only as stated above
2- rotate tire, if noise is still present check wheel bearings and ensure no debris caught between backing plate and rotor
3- if rotating tire does not produce the noise spin the driveshaft while still disconnected from the axle
4- if noise is present remove front driveshaft for thorough inspection and while its out, rotate the front flange on transfer case to ensure noise is not from the t-case

Great idea! I’ll follow that process tonight and follow back up with this thread. Thank you!

g.hayduke · Jun 1, 2020

Does it make the same sound with the other front wheel raised and the driver side on the ground?

Bowhunter · Jun 2, 2020

To follow up, I lifted the axle off the ground yesterday and I couldn’t get the drive line to make the sound again. So I took it for a short drive and then tried it again and still not sound. Only thing I did from when I heard the sound until now is I went for about a 20 mile ride (Including about 10 miles on a semi rough dirt road) on Sunday.

I’ll keep my eye and ear out for the noise and if it returns I will follow Vinmans procedure

Goatman · Jun 3, 2020

Sounds like you had a rock lodged against the rotor or caliper. Hope your luck holds!

Bowhunter · Jun 3, 2020

Goatman said:
Sounds like you had a rock lodged against the rotor or caliper. Hope your luck holds!

I’ve heard the noise for the last couple weeks off and on and thought it was a rock too. But it kept making that light noise and finally traced the noise last week and it just stopped making noise on Monday lol. I hope it was a rock too but there wasn’t any noise coming from the rotor or caliper when I was turning the wheel last week

Bowhunter · Jul 6, 2020

Vinman said:
Before you remove the skid plate try disconnecting the driveshaft at the pinion then rotate the tires again. That will either confirm or rule out the front axle assembly as the source of the noise.
If it were mine I would do the diagnostic in the following order:
1- disconnect the shaft at the axle end only as stated above
2- rotate tire, if noise is still present check wheel bearings and ensure no debris caught between backing plate and rotor
3- if rotating tire does not produce the noise spin the driveshaft while still disconnected from the axle
4- if noise is present remove front driveshaft for thorough inspection and while its out, rotate the front flange on transfer case to ensure noise is not from the t-case

Noise came back today.
I just did steps 1-3. Ran out of time tonight to do step 4. Seems to be coming either from the driveshaft or transfer case (attached video, I had to hold the driveshaft up while also spinning so you’ll hear a lot of extra noise but what we’re listening for the slight grinding/dirt grinding sound.

Front u joint cups were pretty dirty. Needle bearings look ok.

Do you guys think it’s the TC or the U joints in the DS making the noise?

It doesn’t do it all the time, and when it is making the sound it’s the light crunch sound every few seconds. I did notice the sound more prevalent when I was in 4 low climbing a somewhat steep dirt hill road

And on a side notes, the 4 bolts that bolt to the front differential pinion propeller are 14ft lbs of torque correct?

Vinman · Jul 6, 2020

Your video doesn’t work for me. I believe the front driveshaft u-joint to front pinion yoke is about 14 ft/lbs. I would removed the front shaft completely and check the double cardon joint at the other end of the driveshaft, a very common failure point. Search “angry sparrows” for details.

Sancho · Jul 6, 2020

@Bowhunter .. ya i think it is 14 lbs.

L J · Jul 7, 2020

I'd remove the front driveshaft until it's positively eliminated. If it fails it can cause the front half of your transfer case to explode into many pieces.

Bowhunter · Jul 7, 2020

L J said:
I'd remove the front driveshaft until it's positively eliminated. If it fails it can cause the front half of your transfer case to explode into many pieces.

That is definitely a concern of mine. Once the driveshaft has been removed, what’s the best way to see if the noise is coming from the drive shaft? Rotate/move the double cardon joint?

Dirt grinding noise from front driveshaft / transfer case

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