Front Diff Problems....

[Justawajz]

Ok so not sure if anyone has had and similar issues with the ifs dana 35. But I had my regeared awhile back and it started grinding. Took it back had all bearings replaced, after about 50 miles.. again grinding while coasting and accerating. Took it back Again, bearings replaced for the 3rd time.. Like clockwork.. Grinding after bout 50 miles... So fed up I just bought a diff that had already been regeared with 4.56's so I just put that in today. And on the way to work I started to hear a similar noise.. I replaced the transfercase and the both the cv axels.. I have no clue what else it could be. I have the trailmaster kit for my 99 mountaineer so i was thinking mabey the axle isant center. It took awhile to get it lined up while installing it each time.. anyway anyone have a clue??

 

[Justawajz]

Bump....

 

[99SportX]

I got nothing man. I am totally stumped here. Something is putting excessive loads into the diff, so what could it be..........

 

[Justawajz]

I got nothing man. I am totally stumped here. Something is putting excessive loads into the diff, so what could it be..........

Yeah I know right.. It seems I have a unique problem. No one really can give me a straight answer. I've replaced everything I can possibley think it being. Guy was joking with me the other day asking if I replaced the truck yet! ha.. Never!!

 

[ericautopart]

Is this an AWD Mounty? Did you ever remove the front drive shaft to see if that stopped it? Are there metal flakes in the diff oil when drained? Any of the bearings the culprit (pitted, heated, etc)? Does it grind only when on the gas or all of the time?

 

[Justawajz]

Yeah, it was a carrier bearing that had gone out each time. And also both the outter seals. It goes away with the drive shaft removed. When the noise starts its when u let off the gas at hwy speeds. Hit the gas and it will go away for a bit. It kinda comes and goes, my old diff I just drove it and it got so bad it would grind all the time and the gears started howling as well. But yeah it is a AWD, dont know if that could have anything to do with it...? I had bought the superlift driveshaft to replace my factory one. So the last rebuild we put the factory one back it and the started grinding again about the same time.. I really clueless with this at this point..

 

[99SportX]

I remember something about the viscous coupling in the t-case causing a symptom similar to this, but you said you replaced the t-case, so I have no idea. What about your tires? Are they all the same size with even tread and pressure?

 

[Justawajz]

Yeah, that's what we werre thinking so we swapped it out. But the tires are all the same, the rears have alittle more wear than the fronts but it's even side to side. havnt checkd the tire pressure latley, i'll have to check later.

I remember something about the viscous coupling in the t-case causing a symptom similar to this, but you said you replaced the t-case, so I have no idea. What about your tires? Are they all the same size with even tread and pressure?

 

[Justawajz]

Update!
Ok, so I had my front driveshaft double checked again... Took it to a guy that mounted and balanced it and said it was actaully quite a bit off. Said it was a bit bent and had to heat it up and bend it back. Also took some of the weights off and put different ones on. I havnt put it on yet.. could this have really caused all my diff problems so quickly??