Used to have to go to 4lo before 4h

[Redstone]

4x4 works now. After reading tons of useful info here I pulled the shift motor off, moved the shift selector on the tran case so it snapped into 4h, marked the position, which happened to be about 3/4 in to the right of the 4h mark. Pushed the 4h button and tried to line up the motor with the tran case, didnt line up. Moved the position plate about 1/4 in and put motor back on. 4x4 works, BUT now there is a loud clunking noise from drivers side tire. I swapped hubs and cam assemblys from drivers to passengers, no change, so I think not hubs or cams. I spin the tires by hand, no noise. I had replaced the outer universals. On the drivers side I somewhat crushed the ears together removing the old uni, I have removed the shaft and the uni moves freely up and down, left to right. The noise occurs when accelerating ( under load ,or turning ) quiet when just coasting.

So the big question is??? Can the shaft with the crushed ears cause this noise when rotating under load? I thought the worst case would be a bad vibration not a clunk, clunk, clunk. If I knew the rest of the tune I would hum it for you. Ideas, Thanks. I'm thinking this is self induced

 

[92exp4x4]

I would say yes. If the u-joint is damaged and binding then I would say its very possible that it is the cause. But if its not binding up then Something else must be the cause.

Its hard to say to if the transfer case shifter is out of time a little. You may have the sensor out of position in the shift motor. This is how the module knows where the shifter is. Look a little for info on this, I think it is posible to reassemble the motor incorrectly. Your t-case may be jumping in and out of 4x4 lock, and you notice it on the driver's wheel because that is the normally driven wheel on these front ends w/o limited slip.

 

[Redstone]

I would say yes. If the u-joint is damaged and binding then I would say its very possible that it is the cause. But if its not binding up then Something else must be the cause.

Its hard to say to if the transfer case shifter is out of time a little. You may have the sensor out of position in the shift motor. This is how the module knows where the shifter is. Look a little for info on this, I think it is posible to reassemble the motor incorrectly. Your t-case may be jumping in and out of 4x4 lock, and you notice it on the driver's wheel because that is the normally driven wheel on these front ends w/o limited slip.

Thanks for the reply. I pulled the drivers side shaft out and the stub shaft seems to move freely with the long shaft, doesnt bind, I wasnt sure what happens when it rotates under load. I pulled the shift motor off and moved the selector until it snapped into 4hi. I will move the selector to 4lo and see if the clunking is still there. Should there be any play in the end of the axle shaft sticking out from the spindle? I know there is in/out, but should there be up/down, left/right? The spindle bearings look ok, is it possible the axle shaft is bouncing around in the spindle? Any chance you could drive up here and tell me what is wrong with it?