Roar from front end

[YoLev69]

I have a 96 AWD Limited 5.0
OK, I didn't know that having two different Mgf of tires the same size was such a critical issue. I have driven probably 7 or 8K. I never noticed a problem mostly because I don't drive faster than mid 50's generally. I was on the interstate going 70+ and smelled something burning so I pulled to the shoulder. I saw what looked like oil under the car and covering the bottom or everything (blowback) anyhow oil was heavy and dark but the oil was not even a qt. low so must have been front end grease. I slowly went to the next exit and found a Jiffy Lube in where ever I was (GPS's are great). They pulled it over the pit and anyhow long story, I had them check the front dif just to humor me and the check plug was smoking, he couldn't hold it. Things cooled down and they put 4pts. of bulk in and sent me on my way. I drove another 120 miles at 50 and made it home.
Now I have a roar in the front end. It starts around 20mph and continues to about 45 then smooths out. Slowing down (off the accelerator) between 20 and 40 is louder than slightly being under acceleration.
I read the 85 posts about removing the front DS and just want to check back with those that have to make sure I won't have any further problems? Or did I fry things past a cheap fix? Thanks very much for your patience reading this long thread!!

 

[RomeovilleIL]

The differential will still be turning without the drive shaft, you would probably need to cut the axel half shafts and run stubs. But the bigger problem is the truck is AWD as opposed to a 4wd. The viscous coupler might last a couple months but will burn up without the front drive shaft.

 

[YoLev69]

Stub's?

 

[YoLev69]

I must have misunderstood the jest of an 85 post, thread where the bottom line was disconnect the front and back of the front DS and make sure you use the Emergency Break and have a chock available for hills.

 

[RomeovilleIL]

When you read about guys taking out the front drive shaft, it is usually because that drive shaft is damaged. You have a different problem.

Basically even though the drive shaft may be removed, the two half shafts going from the front differential out to the hubs will still be turning. If the differential is damaged, the lack of the drive shaft wont really matter as its the gears inside which are having problems and will keep on turning with the front wheels. It might be somewhat less noisy, but things inside will not be getting better. No telling how long that will last before it binds and breaks.

You cannot just remove the half shafts as they hold together the wheel hubs. You would need to cut the half shaft or disassemble at the cv joints and then drive it with just the outer and inner portions (stubs). The off roaders on the site should have write up about how to do it. They tend to keep pieces like this around in case a half shaft breaks on a trail.

None of this will cost you $$$ and certainly gets rid of the front end noise and danger issues. It will destroy the viscous coupler over time but should keep driving as 2 wheel rear regardless. If you do ever decide to fix it later expect 2 major broken components instead of 1. Then again we are talking about a 15 year old truck, so maybe just part out at that point and buy something newer.