I'm not new to jeeps so little noises squeaks don't bother me. I've owned this one for 10 years and put many miles on her. 3.8 6-speed manual....Lifted w control arms , custom front DS , upgraded steering and regeared all 40,000 miles ago. In the last week I noticed a little tapping from under... nothing big so I ignored. Then today it sounded like an AR unloading rounds lol. U can't even drive without people staring. The video was me turning the wheels at 5mph but when ur at 45mph it sounds insane.

So I get home , was worried possible engine , Tranny, clutch issue. Doesn't seem to be any. It's only acceleration and gets worse as u go faster, once foots off the gas it stops..
So I lift up the rear wheels and throw it in gear and it's definitely from the rear. So I'm assuming rear DS or rear end. Watch the video to get a better idea. I figured I'll take the rear DS off and use 4wd til I can get her fixed. Unbolted the DS on both sides and it won't budge so now it's soaking in PB blaster. I'll try again in the am but have any of u guys had this? Rear DS is still stock , rear end is a D44 w 4.88 gears that was installed 40k miles ago
Let me know what u think

 

It sounds bad in the rear, but is there a possibility that it's an axle shaft in there? It doesn't have the ds sound I'd expect but certainly a heavy metal hitting something else and not happy about it. I think my first move would be to pop the cover and take a look. To reproduce it, just leave it jacked up (with proper supports, yada yada) and turn the tire over by hand while watching inside the diff. I think you'll see what's clunking quickly.

 

Thanks for the reply , small issue ,I just removed the rear driveshaft and took it on a quick drive and exact clunk is still there which would mean the rear diff is no longer a culprit? Right? Since the drive shaft is no longer spinning it or does it still turn w tire rotation?
I'm about to jack the rear up again and throw it in gear and take a peak. It's just hard when ur solo and u drive a stick lol

 

Ok jacked it up spun the rear tires by hand and the clunk is definitely coming from the rear diff. Popped the diff cover and cleaned it. All was looking good till I saw this chunk. That was the only peice. I can't tell where it came from but something took a crap
Now Just need advice.does this call for a whole new gear package and install or just that peice needs to be replaced

 

Allegedly, ring and pinion sets are machined together so you'd need to replace the ring and pinion. Pulling all of it out would put you in the "best practice" category to replace all of the bearings, particularly if there's any metal shavings in the oil which it looks like there may be. Someone who knows a little more may be able to tell you if you can just replace the ring or pinion (it's tough to see from that pic where that chunk came from.

 

You will need to pull out the Diff Carrier and Ring Gear...When pulling the Ring and Carrier out, keep your shims (sides) in correct placement.. Unless the Pinion has something broken you would not need to pull it out.. keeping the shims in order will allow you to re-install the (IF NOT DAMAGED) Ring gear and carrier and keep the proper set up clearances .. Have installed a factory LSD that way and never replaced the gears.. That piece looks like the back of a spider gear .. how much metal did you find inside?

 

I think it might be a chunk of the pinion. That was literally the only peice, no metal shavings or small bits at all, kinda weird.
I'm not sure what would still be causing the continuous clunk though. Is there anything I could do temporary just to get me back on the road and drive in 4wd for a few weeks.My vette is at the shop getting some upgrades and tuners nowadays keep your car for a month even if it's a 5 hr job, so I'm car-less

 

If that is a tooth from the pinion gear...
The clunk happens every time the pinion's missing tooth comes around.
There is nothing you can do to make it temporarily drivable.

 

Yes- there is a temporary solution but it's not fun or easy. If you pull the pinion from the housing and seal up the front end (glove, etc) then you can drive it. That would leave the ring gear in tact which would sling the fluid up and around to hit your rear wheel bearings at the ends of the axle.

I thought briefly on removing the ring gear (pinion would spin freely and not engage anything) but then you're not getting that fluid movement that's necessary to keep the bearings lubricated.

 

Agree with Ron. That sound is almost in time with DS rotation. Probably the aftermarket R/P set.