Thunking and clunking in the front end on and off braking...

tlrtucker said:

So here we go...I lifted the kj ('03 gasser) about 500 miles ago and yesterday a clunking sound developed. I cant figure it out. It sometimes happens rythmically (faster clunking the faster I go), then it doesn't happen. But it always happens going on and off the brakes. If I brake lightly it gets loud, if I brake harder it goes away. And I can definitely feel it in the brake pedal. When I let off it clunks more. When I'm cruising around town under 45 mph it clunks, when I get over 45 it goes away :shrug::shrug::shrug:

I've checked every bolt underneath and it's all good there. I checked caliper bolts, clevis bolts (upper and lower), ball joint bolts, checked the CV axles and they seem fine. There is no play in anything, anywhere...

I'm stuck at work so I cant dive into it and tear the front end apart, so I guess I'm just posting this to see if anyone else has had this problem and traced it to anything....

Any help?

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tlrtucker said:

That's the odd thing - everything functions just fine.

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tlrtucker said:

Is a little bit of slop in the transfer case normal when wiggling the rear drive shaft? Not sure what else to trace it to....taking it to the shop now...damn it!

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dude1116 said:

As in the drive shaft spins 1/10th of a turn or so like the front drive shaft? Yes.

Is the sound coming from the front or rear?

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tlrtucker said:

Yes, 1/10th turn is what I was trying to describe....


I hate this friggin jeep sometimes.....

So I limped it home - it was making a horrible, rhythmic noise dependent on speed the entire way home. In fact, it was so bad I pulled over to see what was hanging off and flopping around.

Got it home, put it on jack stands, pulled the wheels off the front, gave everything a good shake down and nothing appeared to be wrong. Checked both front and rear - nothing.

Started to take it to the shop and the damn thing wouldn't make a sound - nothing close to the sounds it was making earlier. I drove it for about 15 miles and nothing. Took it in to the shop anyway (I only have one vehicle and had to pick up my daughter from daycare, so needed a fix). The mechanic basically told me there was nothing they could do if it wasn't making any sounds.

So...I honestly drove it for another 50+ miles and nothing. I found a dirt/mud shoulder and shifted in and out of 2hi, 4hi and 4lo and it worked flawlessly. I have put another 20 miles on it and it runs like a dream - better than before...


I'm stumped. I've worked on many many vehicles in the past - everything from late model motor swaps, to head gaskets, to lift kits....and I've never experienced anything like this before...

Is it possible that something was just not quite in line after the lift that suddenly "popped into place"????

I'm so confused....and kinda happy that it wasn't an expensive fix....but also worried that the problem might come back.....:shrug::shrug:

Anybody have any thoughts?

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