Front differential question

[Bronco1]

I've got a 96 Bronco XL with the Dana 44 IFS. while I was doing a front end inspection and checking the front drive U Joints, I heard a clunk that seemed to be coming from the front differential when I was moving the front passenger wheel. The u-joints from the front drive shaft seem fine but, when I move the shaft I get a clunk that seems to come from the front diff. I don't hear anything when I put it in 4w high. Does that sound like maybe a bad pinion gear or am I just being paranoid.

Appreciate any insights. Thanks in advance.

 

[Dyusik]

Pinion slack. I used to have to tighten my turdy five quite a bit. See if that helps.

 

[exranger06]

Originally Posted By: Dyusik
Pinion slack. I used to have to tighten my turdy five quite a bit. See if that helps.

You do NOT want to just tighten the pinion willy nilly. Doing so will mess up the pinion bearing preload and will eventually destroy the pinion bearings.
OP: If the clunk is not coming from any of the front u-joints (did you check the one in the middle passenger axle shaft?) there's probably a little backlash in the ring and pinion. If the differential works fine and doesn't make any noises, leave it alone!

 

[Bronco1]

Exranger, yeah I checked the all the u-joints from the transfer case to the wheels. I think the front passenger side is a little worn but that's not where the clunk was coming from. It sounds like the diff. As I said though, it doesn't make any noise in 4h starting stopping or while driving down dirt roads. (I took it down a forestry road yesterday to check it out.) it does have over 250k miles on it.

 

[andyd]

How is the IFS D44 in general. I had solid D44s on the Grand Wagoneers. You would put it in D and awhile later there would be a clunk and off you went. There is quite a bit of lash to be taken up in the entire drive line. If a Jeep doesn't leak, it is probably empty.

 

[Bronco1]

Originally Posted By: andyd
How is the IFS D44 in general. I had solid D44s on the Grand Wagoneers. You would put it in D and awhile later there would be a clunk and off you went. There is quite a bit of lash to be taken up in the entire drive line. If a Jeep doesn't leak, it is probably empty.

I can't complain. I haven't had the Bronco but a few months, and the IFS D44 has done it's job. No clunk while driving, just while I was underneath doing an inspection.