Banging after axle replacement

Nelsonmd

Nelsonmd

New member
My axle replacement went pretty smoothly, but since then I have been hearing a banging or popping that is getting worse. It started happening only when I was turning hard and hitting bumps, but now it has worked it's way to doing it often when turning, and sometimes when accelerating in a straight line.

It sounds like it could be tightly bolted together metal shifting where I cranked the bolts down, but it seems very regular. Not sure how else I can describe it. It sounds like it is coming from the rear but I don't trust my ear that well on that, so it could be coming from somewhere else (it wasn't occurring before the rear axle swap though).

Anyone have any thoughts?
 
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Did your replacement axle have a locker in it? Possibly an Aussie or a Lock-Rite locker? If so that is what you are hearing.
 
No it has an E-locker. You filled it back up with gear oil right? :D
Sounds like you may need to open up the actuator and maybe make some adjustments. Could be that the actuator is allowing the locking mechanism to slide around a little.
 
Yeah, it's an e-locker, and yes I did fill with gear oil.

I have checked all the control arm bolts and panhard bolts and they are tight.

Any other thoughts? I would rather not have to take the actuator off if I don't have to, but if that is the problem, then I guess I will have to.
 
Dammit I was hoping not to hear news like that. Maybe I can add some background info which may or may not be clues to this mystery.
While briefly helping Nelsonmd with the install, we noticed that the input shaft (drive pinion) to the replacement diff had a good bit of backlash to it. Recalling from memory, it had about 10 degrees of play.
Knowing that this is a salvaged rear from a rolled runner, does this give anyone any ideas?
Matt, does your rear end sound normal otherwise besides this intermittent banging noise? No whine and no rhythmic abnormalities?
 
Damn, damn, damn....
I wish I had known about that. Not much I could have done, but at least you would have known before hand.
I'll email the guy I bought the rolled truck from and ask him if he had any rear end issues before the accident.

Stupid question, and maybe un-related... how are your u-joints? Greased them lately?

I hope it turns out to be something simple.
 
Try putting the truck on jackstands.
Push / pull the axle, and tires in all different kind of ways ( front end and rear end )
Might be able to isolate the issue to a specific corner of the truck.
With the turning, might it be CV's?
 
It didn't have 10° of backlash, I played with it quite a bit, and the backlash was really small, and didn't occur every time I turned it. I didn't have oil in it at the time, so it may have been a little sticky, which is why I didn't feel the backlash every time.

I would think that I would feel the backlash when I go from reverse to drive, or from braking to acceleration, and I don't notice anything. I can't really see how that little backlash could cause this popping, unless it was skipping a gear when I turn, but I wouldn't think that is likely without other major signs of a problem. I don't notice any other signs, or noises or anything.

I think the u-joints should be ok, I greased them before I did the axle swap, but I have been meaning to go back and grease them again to make sure I got all of the old grease out.

Like I said, it sounds like it is coming from the rear, but I can't rule out the front or the CV's, because sound location from inside the vehicle is pretty shaky.

If I kick the top of the rear wheels, I do get some noise like something is shifting a little, but it I can't figure out what it is, or if it is the same as the banging I get while driving.
 
Hmmmm...
just trying to think outside the box a bit...

How are your shocks? The shock mounts?

When I changed out the shocks on my '99 ( remember it is originally from Mass. too ) the drivers rear shock stud was rusted completely off and it was banging around quite a bit under there. It ended up pinching & cutting the ABS wire. I still need to fix that :)

How are the rubber bushings for the different bars under there? If they look like mine, they probably could use a replacement.

Spare tire not pulled all the way up?

Have you verified the E-locker is engaging & DIS-engaging? If you are locked in the rear you will get all kinds of funky sounds from the driveline & rear on the street.
 
topdown4runner said:
Hmmmm...
just trying to think outside the box a bit...

How are your shocks? The shock mounts?

When I changed out the shocks on my '99 ( remember it is originally from Mass. too ) the drivers rear shock stud was rusted completely off and it was banging around quite a bit under there. It ended up pinching & cutting the ABS wire. I still need to fix that :)

How are the rubber bushings for the different bars under there? If they look like mine, they probably could use a replacement.

Spare tire not pulled all the way up?

Have you verified the E-locker is engaging & DIS-engaging? If you are locked in the rear you will get all kinds of funky sounds from the driveline & rear on the street.
Click to expand...

EDITED (the sickness I've had is going to my head, and this didn't make much sense)

Shocks are brand new, with new rubber bushings everywhere, the shock mounts are fine, rust free. The control arm and panhard rubbers didn't look too bad, the edge or the rubber was pretty cracked, but that was about it. I didn't realize you can just replace those.

I have no spare tire, it got stolen. I just hooked the harness back up to the e-locker, and it seemed to engage and disengage, but I didn't really verify that it did. I just watched the light turn on and off like it is supposed to. I will try to check that tonight.
 
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Ok, so I havn't been able to crawl under the ole girl with tools due to busy schedule and violent illness, but I did notice something this morning before I went to work. I pushed the back end side to side, and I could see some squishiness in the lower panhard bushing. The upper seemed to be stiff, and the frame wasn't really moving relative to the panhard, but on the lower, I was getting a good bit of movement of the frame relative to the panhard. Is this normal?

My panhard is a little bent (I discovered this when I removed it), and with the bushing appearing shot, I am wondering if I should just get the adjustable one from Sonoran and see if that fixes it.
 
Sounds like that may be it, allowing your rear end to shift around a bit.

Really hope that is the culprit!

Don't know anything about the Sonoran Steel one though....

Good Luck!
 
Yeah, it has actually stopped making the sound when I turn, but I do now get a quieter squeak or bang a bit at random (at low speeds) and fairly consistently when accelerating from a stop.

I would love some opinions on panhard options. Anyone want to go out and shake the booty of their 4R for me and see what theirs looks like? Any reviews of Sonoran's adjustable panhard, or another option out there?

EDIT: I found this alternative panhard, but this is the only one I can find
http://www.dnaoffroad.com.au/products.php?product=4Runner-IFS-rear-Panhard-rod

I also found a stock panhard on Ebay for $70 shipped. Would it be worth it to get stock bushings again?
http://cgi.ebay.com/ebaymotors/ws/e...ssPageName=VIP:watchlink:top:en#ht_500wt_1182
 
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Well, I think I solved this one...

I put it up on stands and got under it tonight, and I found that some of the bolts on the panhard, and control arms had backed off a little bit and were loose. I had tightened them before thinking they might be the cause, and it didn't seem to fix it, but this time it did seem to fix it. I put some locktite on them, so hopefully they won't back off again.

Thanks to everyone for their help. I am very relieved that it wasn't the backlash in the diff causing the noise, cause that would be alot bigger pain.
 
Matt,
I am VERY glad that was all it was.
I was feeling horrible thinking I may have sold you a defective part, even though I thought it was good.
I know the stuff is used, and buyer beware and all that, but still it is my reputation & concience on the line.

I'll sleep better now. :cheers:
 
Well, it isn't completely cured, I am pretty much back to where I started, with an occasional bang while turning and hitting bumps. I think it's gotta be the panhard slipping a little bit. Perhaps now that it is tightened, it is just taking a bigger hit to cause it to shift.

Nathan, I appreciate your concern. Don't worry, I don't harbor any ill will about any defectiveness in the axle you sold me. The reality is, you came up with the only viable option for me. Even if I have to swap out for my old diff, it was still worth it, because I didn't have any other way to get a non-rusty axle for less than retail.
 
Did you ever figure out what the banging noise was cuz I have the same problem. I replaced my axle seal and then the banging started. I have an E-locker also.

It's like it missing a gear or tooth in the axle.
 
cazador#10 said:
Did you ever figure out what the banging noise was cuz I have the same problem. I replaced my axle seal and then the banging started. I have an E-locker also.

It's like it missing a gear or tooth in the axle.
Click to expand...

Yeah, I am 99.7% sure (that's 3-sigma :nerd:) that it was loose bolts. I tightened up all the LCA, UCA, and panhard bolts (some were loose) and put some penetrating lock-tite on them and it went away almost completely. If I take a sharp bouncy corner hard, I do get a bang, but not very frequently.

I did have a recurrence once a few weeks ago, and it was a loose upper panhard nut. I carry tools with me, so while my gas filled, I just crawled under and tightened it up. Problem solved.
 
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