What could this noise be ?

Check your skid plates. My transfer case skid plate was hitting the bottom of my skid plate. I too thought it was in the suspension so I swapped end links, changed LCAs, and transmission mount and still had the noise. Then when I changed my transfer case seal I noticed the powder coat was worn off from it hitting. So then I rearranged my skid plates in how they were layered and added some washers. The noise went away kinda, but was still there. I finally figured this out last week. Since I put my engine/transmission skid on top of the transfer case one the steering rack cross member was hitting the engine skid. I made some spacers out of aluminum bar stock and the noise is gone now. Thank God. Hopefully yours is a simple solution like this too. I know I'm not the only one who has had this problem with aftermarket skids.
 
Check your skid plates. My transfer case skid plate was hitting the bottom of my skid plate. I too thought it was in the suspension so I swapped end links, changed LCAs, and transmission mount and still had the noise. Then when I changed my transfer case seal I noticed the powder coat was worn off from it hitting. So then I rearranged my skid plates in how they were layered and added some washers. The noise went away kinda, but was still there. I finally figured this out last week. Since I put my engine/transmission skid on top of the transfer case one the steering rack cross member was hitting the engine skid. I made some spacers out of aluminum bar stock and the noise is gone now. Thank God. Hopefully yours is a simple solution like this too. I know I'm not the only one who has had this problem with aftermarket skids.

You know, good call. I will definitely have to look at this. I to have savage off road transmission/transfer case skid plates. And the front engine one is rat off road one. I did notice the steering rack being very close to my front skid plate. I added 2 washers and it seemed to be cunt hair of the rack. However I never removed the old skid plate on the transfer case.

Did you expiernce noise when turning ?
 
You know, good call. I will definitely have to look at this. I to have savage off road transmission/transfer case skid plates. And the front engine one is rat off road one. I did notice the steering rack being very close to my front skid plate. I added 2 washers and it seemed to be cunt hair of the rack. However I never removed the old skid plate on the transfer case.

Did you expiernce noise when turning ?

Yes my symptoms we're just as you described. I'd hear it turning in parking lots, backing out of the driveway, going through a large pothole or dip slowly where weight shifted to one side of the truck. If your transfer case still has that tiny black metal skid on it I could see that it would easily hit the Savage skid. My shrockworks skids have less than a cm clearance without that stock skid.
 
Yes my symptoms we're just as you described. I'd hear it turning in parking lots, backing out of the driveway, going through a large pothole or dip slowly where weight shifted to one side of the truck. If your transfer case still has that tiny black metal skid on it I could see that it would easily hit the Savage skid. My shrockworks skids have less than a cm clearance without that stock skid.

Where did you get the aluminum from ? Home Depot ? Or just local supplier ?
 
Do we have steering stoppers that people talk of ?

Yes, its the small flat spot on the lbj that contacts another flat spot on the lca but unless the noise only happens at full lock I doubt that's where the noise is coming from.
 
Where did you get the aluminum from ? Home Depot ? Or just local supplier ?

Lowe's. I just used 1" wide, 1/8" thick aluminum. I got a 3 foot bar and cut it to length and drilled holes where the skids mounted. Then just placed it between the frame and skid plates.

Try pulling your skid first and see if it makes the noise go away.
 
When I replaced my sway bar end links I put the bushings on in the wrong order and had metal on metal contact. It made a terrible popping and jingling sound when I was going slow and going over uneven ground.



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