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Discussion Starter · #1 ·
The front differential on my truck is making a loud grinding, clanking, rattling sound I've tried looking online everywhere to assess what the problem could be and found nothing I'm wondering if anyone else has had this problem and if so what could be some causes, and solutions? I thought it was the bearing at first so I've replaced both front wheel hub bearing assemblies and U-joints but the noise and burnt grease smell continues. The 4WD is out and wont actuate at all probably due to whatever is casuing the sounds and smell. Also is there anywhere I can just buy a complete rebuild kit for the front differential that has everything I'll need to rebuild it completely? Any help will be greatly appreciated.
 

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This happened to my truck, too. I solved it by changing both the front u-joints. If you have changed both the front U-joints, try pulling the front hub/axle assemblies completely out and check to see if there is any damage to the splines. If so, there is something broken and rattling around inside the axle. Otherwise, remove the vacuum shift actuator assembly (located on the passenger side of the axle) and examine the cavity for damage or loose or broken components.

Hope this helps, I wish I could be of more assistance. If you need any step by steps or anything else, feel free to PM me!
 

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Discussion Starter · #3 ·
Thank you for the help, I appreciate it. All the splines are good to go, I'll check the vacuum lines and what not to see if thats a factor. I'm hoping it's just the yolk from the front driveshaft, tried looking for a front differential rebuild kit becuase the dealer wants 2 grand to rebuild it or replace it. I may just save up and by a Dana 60 variable slip front differential to slap on it. Bad thing is this truck is becoming a money pit but I've dumped too much into it not to finish, Only things left is the front differential problem, and I need a new linkage rod for the shifter and transfer case. I have a K&N air intake for it, and will be getting a throttle body spacer to further help with gas mileage, after those are installed I'll be done and it should be good to go. Thanks for the help any other advice feel free to message e or post on here I appreciate it.
 
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