2005 Libby: 4wd noisy, metal on metal/clicking

I've got a 2005 CRD with about 200,000 miles on it. Took it off roading recently and on the way back we were getting an awful noise in 4wd, coming from the front. It is loud and unbearable, very loud metal on metal, grinding, clicking noise. Occasionally, when in 2wd on pavement I will hear the noise as well (but MUCH quieter), however, it does not change while turning, it is constant. After some research, and getting under the car here's what I've found:

-The Front CV joints are good, boots are also good, no noise change when turning

-Rotating the front drive axle there was no play

-The boots on the front driveshaft are in tact and in good condition

-When rotating the front driveshaft by hand there is play, and it is noisy, almost like the noise is reverberating through the shaft

-I just changed my front differential fluid and it was nasty, but didn't have any pieces of metal in it, that I saw anyways.

So, I think I'm left with the problem being that the front differential is shot.

How do I isolate this problem? Disconnect the front driveshaft from the transfer case and rotate to see if the noise is still present?

Stuck rock scraping against something? Sounds stupid I know. Common behind brake rotors too


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I'm not expert, but I'd pull the front drive shaft and go for a drive to see if the sound is still present. It's pretty easy and simple to start there. It's OK to drive without it, just don't pull the 4x4 lever.

Are you sure the CV joint at the transfer case end of the front driveshaft is intact?

With 200K miles I'd be shocked if it was still in working order. They are exposed to all the road junk that gets thrown up by the front tires and they can make some nasty sounds. Since the sound happens in 2WD as well as 4WD that's where I'd start - go with the cheap fix first (about $50 from driveshaftparts.com.)

Have you changed the transfer case fluid?

Bob

I really doubt it's the front diff. That's not a common failure from wear.

The boot might be intact but 200k will wear it out even with a good boot. I'd replace both joints on the front shaft. It could also be the intermediate shaft, mine was well wallowed out with 140k on it. See if there's a lot of play where it connects to the passenger side CV.

Where in MN are you? I'm just across the Mississippi in La Crosse.

I haven't done the transfer case fluid yet. Will attempt soon and report back. Thanks guys!

I'm actually in Northern Michigan...I need to change my location...

So what'd you find out?