Front Axle Noise

[85_Ranger4x4]

Does it make noise going straight? Wheels turned?

Dry needle bearings in a u-joint or bad spindle bearing are also the first things to come to mind. That said I have seen and driven plenty of trucks that are just missing the spindle bearing, seal/thrust washer/outer washers & clip and they made no noise at all.

You'd think if it was something in the t-case or differential it would make noise in 4wd with the hubs unlocked so it seems safe to me to rule that out.

Like going down the highway at highway speed. If the wheels are turned not much and I didn't notice it making a difference.

 

[4x4junkie]

Seems it wouldn't be a U-joint then (U-joints tend to show themselves mostly when the wheels are turned, less so when straight).
At this point I'd say a teardown is really the only way you're gonna find out for sure what it is. Make some plans for a loaner vehicle if you don't have something else to drive for a week or two while you chase down replacement parts.

 

[dvdswan]

Thrust washer?

 

[85_Ranger4x4]

Seems it wouldn't be a U-joint then (U-joints tend to show themselves mostly when the wheels are turned, less so when straight).
At this point I'd say a teardown is really the only way you're gonna find out for sure what it is. Make some plans for a loaner vehicle if you don't have something else to drive for a week or two while you chase down replacement parts.

I was hoping to knock it out quick at work on a lift in the heated shop on a saturday this winter. Looking more like a drafty old garage project...

 

[bobbywalter]

sounds like normal ford noises to me

 

[85_Ranger4x4]

Had a brainy idea tonight.

Backed it into the garage, kicked the rear into neutral and the front into gear. Stuck the trans in gear and jumped out for a looksie. You can hear the pulsing chuffing sound. No idea why but I had it in low range and in overdrive (I was trying to get close to highway speed but bumbled it)

So I slipped it apart.

Less than perfect



Spindle cleaned up nice though.



Grease on the shaft was dark but not the groady orange color.



Bearing looked ok, grease is dark but there and not dry at all.



Anyway, plastic washer is there and greasy so i did that right. Shaft where the spindle bearing runs is on the rougher side, kinda wondering if that is the cause. This axle was EXTREMLY neglected when I got it, I had to break a seized u-joint apart to get the knuckle off, one ball joint had actually worn a hole in the cup etc. I suppose I figured it I would try it and see how it went... and then it took me 5 years to get a driveshaft to fit in it full time and between here and there I forgot.



Wheel bearings look ok for the most part, oddly the grease in the rollers is still nice and green.






Current plan is to touch up that bearing surface with a little emery cloth, repack the wheel bearings and try to clean and regrease everything else and see if it makes a difference.

 

[bobbywalter]

yup. normal ford noises... gonna have that.

 

[85_Ranger4x4]

yup. normal ford noises... gonna have that.

In this configuration with the hubs unlocked and the t-case in gear I can't hear the noise going down the road so yeah, probably within the realm of normal.

With the hubs locked and the tcase in neutral it is that pulsing noise but to the sound level of a bad wheel bearing. It sounds like something is seriously wrong.

I wonder if having the tcase engaged helps dampen the noise or something. It will also do it with the driveshaft not in the truck so it is not related to that.

But since it runs dead silent with the hubs unlocked I don't think it is a wheel bearing.

 

[pjtoledo]

that last bearing picture looks like the inner race is rotating on the spindle more than the rollers roll.

 

[Roert42]

that last bearing picture looks like the inner race is rotating on the spindle more than the rollers roll.

second that, especially looking at the picture of the shaft

 

[85_Ranger4x4]

The grease was filthy with water so the spindle is kinda trying to flash rust a day later, I dont see any signs of a bearing spinning though.

 

[pjtoledo]

the rusty grease is a tell-tale sign of fine metal particles.
what does the bottom of the spindle look like?

 

[Curious Hound]

I agree the top looks good. But check the bottom since the weight bears down in that direction. If bottom looks good and the bearing has a good fit, go with it.

 

[85_Ranger4x4]

I forgot to get a pic this morning, I can see where it has been turning some on the bottom. Not much wear, almost like a change from the usual machine finish to more of a polish. Can barely catch it with my fingernail.

I have it in my other truck, I am going to get my dad to take a look at it. I think it will be ok.

Anyway back to the reason we are here, found my spare axle shaft in the barn. Where the spindle bearing runs on the shaft is dang near perfect on it... so I think I might throw a new ujoint and seal kit on it and promote the one that is in the truck to spare.

 

[85_Ranger4x4]

Ran dad down in town today and showed him the spindle. He said more or less said "I wouldn't risk it, but I don't know if a new aftermarket one would really be much better"

I have a good used spindle with no wear at all so I figure it would be good to keep the one off the truck around for an emergency spare. Of course when the pinhead pulled the spare spindle that is probably going on the truck they had to hit it several times on the seal area so I have that to deal with... maybe a speedi sleeve I dunno. It is almost worth buying a new spindle to just not have to deal with replacing the POS spindle bearing again.

I keep forgetting the stupid thing in the truck to get a picture though.