94 Explorer is making noise after regearing.

[nmfordguy]

Hey guys just curious if anybody had run into this before. about a month ago we regeared our huntin rig its a 94 ex with a dana 35 upfront. I did the install the first round and drove it around A few days and notice like a bearing noise /grinding sound. sounds to me like its coming from the front diff. The weird this is it only makes this noise when i lock the manual hubs. when i engage the transfer case (bw 1354)the noise goes away. thinking to myself maybe we didnt get the gear set up just right.
so i take into a shop and have them recheck everything and the setup the gears a second time. I get it back last night and its still making this noise. Pretty much everything up front is brand new. Bearings/rotor/brakes/ ball joints/ ring pinion bearings inside the diff./ new warn hubs.

Anybody run into this before?

 

[BrooklynBay]

Welcome to this forum! I've moved your thread into the stock 91-94 section.

 

[92exp4x4]

The only thing you didn't mention is the u-joints in the front driveshaft. I guess its possible for it to make noise while trailing but not being driven, i.e. the hubs locked and not in 4x4. Maybe the joints shut up when recieving torque from the transfer case in 4x4. Just a guess, I've seen wierder stuff.

Post what you find.