Installed a new front shaft the other day and was getting a click/pop sound from the front end, hard to tell exactly where though. It happens when I first start to release the clutch in 1st from a stop. I can't hear anything after ~5mph or once power has been applied. I had replaced both the diff and t-case yokes with aftermarket u-joint yokes. Took the shaft off and torqued the pinion nut a little more (didn't replace crush sleeve, just tightened the nut back by feel) but the sounds still there (even with no shaft). Sometimes it's a grinding noise others its a clipop' sound....Yesterday had a mechanic friend check it out and we determined the axle is fine. Leads us to believe something happened to the t-case. Does the t-case output nut have a specific torque?..At a loss if anyone has any thoughts.

 

Did you check it for zip-tie's ???

 

Ya ya lol laugh it up. Yea we took the shaft off and inspected it for any burrs from casting an such an found nothing. We decided to leave the shaft off and the noise is still there. Maybe I should move this to the stock section? The only other things touched were the front diff and the t-case, and it doesnt seem to be the diff.

 

Your T-case isn't turning without the shaft, gotta be in the frt diff. Did you try 4wd when you had the shaft in?

 

Yea in 4wd with the shaft in the noise was not there.

 

Probably cause it provided tension on the frt yoke. I dunno much about differentials, but I would say you don't have the right torque in the front. Also , I know people get away without doing it ,but a new crush sleeve shoulda been used.

 

Yea i know, I'm gonna take the front diff apart tmrw I think. I plan on doing 5.13's soon anyways so maybe I'll just do it all at once.