Front end noise - 60 Series

[Cruisertrash]

Alright Rising Sun brain trust, what do you think??

-Front end clicking/popping/thunking noise.
-Only in 4 Low, maybe happens in 4 High, but possibly not enough rotation to tell
-It is not happening with every rotation of the tires, but it happens a lot. It will happen several times in a row, then stop, then do it twice, then stop, then again, etc
-Mostly happens when there's some amount of suspension flex/movement, even small.
-Happens while going straight or while turning
-Happens in 4 Low with the hubs unlocked
-Happens in 4 Low with the hubs locked
-Does not happen at all in 2 Low (transfer case is modified for true 2 Low - the transfer case does not spin the front output flange)
-Shackle reversal with ~5" of lift
-1982 truck with "short" H42
-Early front driveshaft with double cardan at the top, single u-joint at the bottom

What I've checked:
-Tie rod ends: the all feel good, replaced about 18 months ago
-Wheel bearing play: none, full knuckle job done about 12 months ago
-Steering box: rebuilt two months ago, feels tight, no leaks
-Steering linkages: mostly straight, doing what they're supposed to be doing
-Rub: I can't see anything rubbing when the wheels are straight or turned
-Front brakes: no loose bolts, both work, everything appears to be tight

 

[Hulk]

How's your driveshaft looking? Can you squirt some grease into the U-joints?

 

[DaveInDenver]

How's your driveshaft looking? Can you squirt some grease into the U-joints?

Sure does sound front driveshaft or maybe front diff related.

 

[Crash]

Have you removed the front driveshaft and given it a look? Slip joints can get very worn and sloppy.

 

[Cruisertrash]

Driveshaft rebuilt by Bill’s maybe 12-18 months ago. However the angle of the lower u-joint should be zero and it’s about 13*. I suppose the front u-joint could have blown out already. I did have Bill do a lengthened spline and clearance all the yokes because my operating angles are higher than normal. I grease the u-joints (and not the slip joint) 3-4 times per year. I did that maybe back in April when I had the driveshaft out for the transfer case rebuild/replacement.

 

[fyffer]

Had something very similar, so other than above considerations are to re-Torqued the Body mounts ( I did after changing them) and replaced the steering dampener/front shocks. It helped me.
But also check your leaf springs, if any of them broken will also click and definitely clunk. Assuming you replaced bushings to shackles, with your reversal. Greasable bolts to shackles are nice, fyi.

 

[Cruisertrash]

Had something very similar, so other than above considerations are to re-Torqued the Body mounts ( I did after changing them) and replaced the steering dampener/front shocks. It helped me.
But also check your leaf springs, if any of them broken will also click and definitely clunk. Assuming you replaced bushings to shackles, with your reversal. Greasable bolts to shackles are nice, fyi.

Thanks Mike. The leaf springs and u-bolt flip plates were done earlier this year. The front body mounts (the worst ones on my truck) were replaced in April. The front shocks are old though - they came on the truck when I got it.

Anyway, even if I have done some of that work recently it's worth checking again.

 

[RDub]

Have you tried 2wd but with hubs locked? Probably not a whole lot of info to be gained, but it could rule out t-case, unless your output bearing is wonky. Can you post a video or audio grab?

 

[Crash]

Retorque the u-bolts on the flip kit. I needed to several times after installing the same kit you have. If I remember correctly you want to put your floor jack under the u-bolts to take the load off the nuts you are tightening. Even if it won’t do anything for your clunk it will allow you to properly torque the bolts.

 

[Cruisertrash]

@RDub I tried recording it but it's impossible, it doesn't come through on the phone. I will try 2 Low with the hubs engaged.

@Crash I experienced that with the rear u-bolt flip plates that I installed last year. Front ones have been retorqued maybe three times ... doesn't hurt to do them again though. I never thought about putting a jack underneath to take the load off too. Brilliant.