Knocking: front brakes, rear brakes, drive shaft(?) Ujoints Or Drums? Help?

VanBCguy · 12-19-2009, 04:30 PM

So I took my '03 TJ to a very professional "Jeeps only" mechanic that has an excellent reputation. I bought a used package from a guy I know of locally that maintains his equipment very well but was upgrading to a Hi-9 (amongst many other cool things). The kit includes: RE 4.5" Long arm kit, wheels, complete front and rear D44's with 5.13 gears, an ARB rear locker, Warn manual hub conversion on the front, etc. I had anything (bushings, u-joints, etc.) that were worn replaced with new parts.

When I drove it away, I immediately encountered tremendous squeeling from the rear. I took it back, we looked at the brakes and determined that the pads had seized to the rotors. We backed the e-brake off and decided that driving would take the problem away. Sure enough, time has shown that it has taken about 99.9% of it away.

Driving home seemed quite nice. Nice power, no death wobble, stiff springs (new and expected), speedo off (expected), but seemingly and essentially no issues. But take into account that this rig has been sitting inside a shop for almost a month, dry and warm.

I drove the Jeep in the next few days just to get a feel for it and see if everything was "buttoned up" as it should be. Within a day or less, I start to feel a clunk under my butt when shifting, I can feel that 1st to 2nd gear is like a don't have a synchro but it went to the build shop in fine condition and shifted smooth as silk previous to the build. I quickly learn that 1st and 3rd (most especially) but also 5th aren't holding in gear. They pop out when torque is put on. I pull the shift boot off and see that the tranny has shifted up and forwards and the shifter is contacting the top front of the centre console. I go to another shop that I know of and is closer to home and have it Dremel'd out. 1st and 3rd gear problem solved. But the others just keep getting worse.

I read a thread here recently (and admittedly, unintentionally hi-jacked it). It asked if the thunking that the OP was encountering could be from u-joints or drums. This got me sussing things out. I went back to my "Dremel" shop and had the tranny looked at. They found the 4 bolts that go through the skid plate from the tranny only had 3 nuts on them and the 3 that were there were 1/2 way backed off. That was tightened up and my rear gear oil level was checked. My e-brake was tightened as well as my rear discs. were adjusted. Upon driving away, things seemed a LOT better. But time would tell...

Time would tell me that things were different, not necessarily better. My 2nd gear synchro still seems shot, I'm still getting thunks under my butt and weird thunks from my brakes (front more than rear) but are less severe than when the tranny wasn't bolted to the skid plate properly. Occasionally it feels as if my driveshaft makes a thunk under my butt. It's enough to be noticeable to passengers. I get a thunk and a sort of bang from the front drivers side brakes when I first start moving. This goes away very quickly. I get the same from the rear, but it goes away a little more slowly.

On a final note, things minimize after driving and heat builds up. I'm guessing warmer fluids/oils are the reason. I have talked to the shop that did the build for me and they were shocked and bothered by the fact that the tranny wasn't bolted properly, the description by me that I feel like I'm driving a Jeep with a "glass driveline" is seemingly disturbing to them and I'm trying to suss out what the problem(s) is/are before I go back and get them to adjust or fix things.

Any help, advice, opinions, etc. would be appreciated.

Thanks in advance.

VanBCguy · 12-20-2009, 02:23 AM

Bump for help?

VanBCguy · 12-20-2009, 08:22 PM

Help? Please?

**Divinitous** · 12-20-2009, 10:30 PM

Maybe the arms bushings. I know that the RE bushings have a terrible reputation and once they get ovalized people start to get funny clunks when shifting. Make sure everything is tight. All control arm bolts and such.

VanBCguy · 12-20-2009, 11:06 PM

Quote:

Originally Posted by Divinitous

Maybe the arms bushings. I know that the RE bushings have a terrible reputation and once they get ovalized people start to get funny clunks when shifting. Make sure everything is tight. All control arm bolts and such.

I'll check all those. But I've been assured by the build shop that all bushings that even looked like they needed replacing have been replaced.

Pillswoj · 12-21-2009, 07:37 AM

If the shop is truely shocked about the loose tranny bolts then take it back to them and have them diagnose it and check everything they did. I would think it would be a free service as you had major work done and are not satified. Is this an independent shop or a 'national' chain? Although they are never the best price, National out my way always stands behind their work.

**Divinitous** · 12-21-2009, 09:14 AM

Quote:

Originally Posted by VanBCguy

I'll check all those. But I've been assured by the build shop that all bushings that even looked like they needed replacing have been replaced.

Set the e-brake and have someone watch the axle as you feather it into the gears. Have em watch for the axle rotating.

VanBCguy · 12-21-2009, 03:32 PM

Thanks for the responses guys. I'll try as suggested. Keep the posts coming though...I'm still boggled by this 2nd gear synchro-like issue.

MJMPC · 12-21-2009, 03:51 PM

When I drove it away, I immediately encountered tremendous squeeling from the rear. I took it back, we looked at the brakes and determined that the pads had seized to the rotors. We backed the e-brake off and decided that driving would take the problem away. Sure enough, time has shown that it has taken about 99.9% of it away.

Could you tell us a little more about this . Were the rotors rusted very much ?

**wushaw** · 12-21-2009, 05:43 PM

So you got new dana 44s and in less than a month the pads seized to the rotors? Something sounds amis there.

VanBCguy · 12-21-2009, 06:03 PM

Quote:

Originally Posted by MJMPC

When I drove it away, I immediately encountered tremendous squeeling from the rear. I took it back, we looked at the brakes and determined that the pads had seized to the rotors. We backed the e-brake off and decided that driving would take the problem away. Sure enough, time has shown that it has taken about 99.9% of it away.

Could you tell us a little more about this . Were the rotors rusted very much ?

We never looked at the rotors. We both knew this was what had happened since between the time of the previous owner taking them off his LJ and them arriving at the shop for install on my TJ, they had seen a bit of inclement weather. The squeeling is 99.9% gone now and the rear brakes have been tightened (both the discs and the e-brake).

Quote:

Originally Posted by wushaw

So you got new dana 44s and in less than a month the pads seized to the rotors? Something sounds amis there.

It would be amis especially if the D44's were brand new. But as mentioned in my initial post and the post above, these are used D44's. New to me, but used. They were checked thoroughly before install though. The squeeling really isn't that bad now. 99.9% gone and now it's the thunking and thumping I'm more worried about. I think I'm looking at a front and rear brake issue, but I could be wrong. Especially since that idea doesn't make sense to the issue of the problem disapating almost completely when the fuids and oils have had time to warm up after driving a bit.

tims03TJ · 12-21-2009, 06:04 PM

is it real stiff when you try going into gears or coming out or both

VanBCguy · 12-21-2009, 06:05 PM

Quote:

Originally Posted by tims03TJ

is it real stiff when you try going into gears or coming out or both

No, I wouldn't say the shift, up or down, or both, is really stiff. Stiffness doesn't seem to be an issue. It's 1st - 2nd synchro that's the issue.

VanBCguy · 12-31-2009, 05:39 PM

Bump for thoughts on this?

And an excuse to any and all JF'ers that read this thread! Cheers to you all!