Clunking noise - JeepForum.com
 
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post #1 of 14 Old 08-08-2010, 08:20 PM Thread Starter
adub2006
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Clunking noise

Over the weekend i swapped the front axle (D30) in my 06 TJ with a pullout front axle from a 97 TJ. The new axle is a D30 with 4.10s to match the rear axle I already swapped in. Drove it a couple miles yesterday to some trails to test it out, did some light offroading for 30 min or so and came home. Drove it a couple miles today and noticed a clunking I could hear (not loud) and feel in the floorboard. Most pronounced on light bumps and while steering. I used an impact on all the bolts when I reinstalled the axle, but I double checked anyway. Nothing loose. Checked the ball joints on the new axle to make sure they were tight and they are. It reminds me of exhaust pipe hitting the floorboard on a previous car. I checked the motors mounts and trans mount (only a month old) and looked for anything loose. Can't seem to find it. Any ideas?

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post #2 of 14 Old 08-08-2010, 08:25 PM
jeepin-gheenoe
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is it when you are only moving?

and if it is when you are moving does it steadly faster?

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Quote:
Originally Posted by AlexTJ View Post
While we're at it lets sue the pants off 'em for ever considering using the dana 35!
Quote:
Originally Posted by TJorange View Post
Your Jeep is a real work horse man! Seems like ive seen at least one picture of it on every page of this forum.
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post #3 of 14 Old 08-08-2010, 08:43 PM Thread Starter
adub2006
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only when moving, not related to speed
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post #4 of 14 Old 08-08-2010, 08:47 PM
jeepin-gheenoe
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i had a very similar noise come up in my jeep to about 2 months ago, turned out to be a U-joint going out.

but since your problem isnt relevent to speed it cant be the U-joint.

might as well check it out since your pokin around the jeep. thats always good.

2005 Wrangler LJ (patriot blue with matching body&fenders like a sahara), auto, D44 rear Limited Slip Diff, D30front open, 3.73, 1 1/2inch RC spacer lift, K&N CAI, 31/10.50 kelly safari tsr A/T's, custom grill guard, warn 3700 winch, 5" KC Apollo long range lights, 1500watt SSL amp pushing a 12 inch kicker CRV sub, Flowmaster 40seriers muffler with custom side exit crome tip and lots of CROME!


Have an LJ and need a hard top...clicky here!
Check out my Jeep and my Gheenoe in
actoin on my youtube Channel

Quote:
Originally Posted by AlexTJ View Post
While we're at it lets sue the pants off 'em for ever considering using the dana 35!
Quote:
Originally Posted by TJorange View Post
Your Jeep is a real work horse man! Seems like ive seen at least one picture of it on every page of this forum.
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post #5 of 14 Old 08-08-2010, 08:48 PM Thread Starter
adub2006
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I replaced the front driveshaft to front axle u joint during the swap
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post #6 of 14 Old 08-08-2010, 08:49 PM
jeepin-gheenoe
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just thought of somthing...check the rubber bushings on your shocks...i had some from rough country go out on my and it sounded identicle to you problem!

2005 Wrangler LJ (patriot blue with matching body&fenders like a sahara), auto, D44 rear Limited Slip Diff, D30front open, 3.73, 1 1/2inch RC spacer lift, K&N CAI, 31/10.50 kelly safari tsr A/T's, custom grill guard, warn 3700 winch, 5" KC Apollo long range lights, 1500watt SSL amp pushing a 12 inch kicker CRV sub, Flowmaster 40seriers muffler with custom side exit crome tip and lots of CROME!


Have an LJ and need a hard top...clicky here!
Check out my Jeep and my Gheenoe in
actoin on my youtube Channel

Quote:
Originally Posted by AlexTJ View Post
While we're at it lets sue the pants off 'em for ever considering using the dana 35!
Quote:
Originally Posted by TJorange View Post
Your Jeep is a real work horse man! Seems like ive seen at least one picture of it on every page of this forum.
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post #7 of 14 Old 08-08-2010, 08:52 PM Thread Starter
adub2006
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not the shocks. Shocks are skyjacker hydros only a couple months old. Double checked top and bottom mounts today.

FWIW Jeep has a 4" Pro Comp short arm lift and 33s
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post #8 of 14 Old 08-08-2010, 09:02 PM
jeepin-gheenoe
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you mentioned it sounds like an old exhaust problem from another car you owned...did you check to see if all exhaust pipes are snug?

what about any deffects in the newly instailed axle?
such as all bearings and u-joints in good condition?

other than that im stumped...well besides checking the rear axle...

2005 Wrangler LJ (patriot blue with matching body&fenders like a sahara), auto, D44 rear Limited Slip Diff, D30front open, 3.73, 1 1/2inch RC spacer lift, K&N CAI, 31/10.50 kelly safari tsr A/T's, custom grill guard, warn 3700 winch, 5" KC Apollo long range lights, 1500watt SSL amp pushing a 12 inch kicker CRV sub, Flowmaster 40seriers muffler with custom side exit crome tip and lots of CROME!


Have an LJ and need a hard top...clicky here!
Check out my Jeep and my Gheenoe in
actoin on my youtube Channel

Quote:
Originally Posted by AlexTJ View Post
While we're at it lets sue the pants off 'em for ever considering using the dana 35!
Quote:
Originally Posted by TJorange View Post
Your Jeep is a real work horse man! Seems like ive seen at least one picture of it on every page of this forum.
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post #9 of 14 Old 08-09-2010, 06:25 AM Thread Starter
adub2006
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I didnt check for loose exhaust bolts, but I did check the hangers. I assumed since there is no exhaust leak sound the bolts were tight, but I should check those.

Whats the best way to check the bearings and u joints in the new axle?

Drove it to work this morning which is about 30 miles. It will occasionally make noise while going straight, but its very noticeable when turning and moving, but you have to have to some speed. Turning into a parking spot does not cause any noise.
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post #10 of 14 Old 08-09-2010, 08:58 AM Thread Starter
adub2006
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Also went out and tried pushing down on the bumper and rocking it side to side with it parked. It won't make the noise doing that
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post #11 of 14 Old 08-09-2010, 08:10 PM Thread Starter
adub2006
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Went through and torqued it all to spec tonight. Sway bar was off center, but fixing that didnt make a difference. Removed all loose items from the interior, no dice. Pulled the front DS to make sure it wasn't the culprit and the noise stayed. Double checked motor and trans mounts, also made sure exhaust was tight and all mounts were in good shape. It really sounds like something is banging against the drivers floorboard, but there is nothing there?? Jeep has a tcase drop so there is even extra clearance!
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post #12 of 14 Old 08-09-2010, 08:22 PM
jeepin-gheenoe
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make sure all skid plates are tight to...

this is strange...it sounds like we have covered everything that could be the culprit...

2005 Wrangler LJ (patriot blue with matching body&fenders like a sahara), auto, D44 rear Limited Slip Diff, D30front open, 3.73, 1 1/2inch RC spacer lift, K&N CAI, 31/10.50 kelly safari tsr A/T's, custom grill guard, warn 3700 winch, 5" KC Apollo long range lights, 1500watt SSL amp pushing a 12 inch kicker CRV sub, Flowmaster 40seriers muffler with custom side exit crome tip and lots of CROME!


Have an LJ and need a hard top...clicky here!
Check out my Jeep and my Gheenoe in
actoin on my youtube Channel

Quote:
Originally Posted by AlexTJ View Post
While we're at it lets sue the pants off 'em for ever considering using the dana 35!
Quote:
Originally Posted by TJorange View Post
Your Jeep is a real work horse man! Seems like ive seen at least one picture of it on every page of this forum.
jeepin-gheenoe is offline  
post #13 of 14 Old 08-09-2010, 08:28 PM
aussied97tj
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Control arm bushing good? Might be worth checking axle/frame ends.
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post #14 of 14 Old 08-09-2010, 08:29 PM Thread Starter
adub2006
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I checked those too, nice and tight

I think I figured it out. I forgot to mention....Jeep was 2wd only for about 2 months while it had 4.10 rear gears and stock fronts. After I put in the axle, I hit the dirt and put it in 4hi and nothing happened. 4wd shifter was loose. Went back to the house and the pivot rod was out of the mount. I fixed it and thought nothing about it (its a lifted Jeep right?). After researching tonight, it seems this is a common issue related to the tcase drop I have. Symptoms sound just like the noise Im getting. Won't be able to check it until tomorrow, but I will confirm and order the AA adapter kit.
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noise , clunking , tj , wrangler , d30 , dana 30 , swap , replacement

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