Rotational clunk just started

[gitslashgin]

So, on my way back from picking up my girlfriend today at work this new sound started coming from what i think to my best guess is the rear end. I drive a 1989 Comanche Pioneer 4x4 4.0 manual. It has a 5" lift from rocky road outfitters using a spring over axle setup with drop control arm pockets. Everything has been fine (less a misfire that happened about a month ago from low compression) up until now. I am quite used to my misfire sound coming out of my tailpipe, but this is something else. With the truck not in gear but rolling I can still hear the noise, it's definitely something new. Anyone had this issue before? I can only think that my axle is severely worn.

[gogmorgo]

Check your lug nuts. It may seem obvious, but it can happen to anyone. I'm still convinced someone stole a couple of mine this summer...

U-joints are also an easy check. Your lift (I guess any and every lift) would put sharper angles on the joints, which will accelerate wear.

[gitslashgin]

I'll check both, I do have a 1" t-case drop to make the angle somewhat better, but it's still not ideal i'd say.

 

Update:

Checked the lug torque, most rear ones were good to go, a few of the front ones needed about an eighth of a turn tighter. U-joints seem good.

[gogmorgo]

The tcase drop will make the problem worse unless you change the pinion angle to match. The pinion shaft and tcase output shaft should be parallel.

[HOrnbrod]

Driveshaft geometry

 

I'd suspect u-joints especially if they are the same ones you had pre-lift.

[gitslashgin]

Yeah, they're parallel. I pulled my differential cover today and found 3 teeth on the ring gear missing, sitting in the bottom of my differential. So, goes without saying the dang thing needs replaced. Unfortunately I can't find a dana 35 with 3.08 gears anywhere near me. I'll be parking it and scrounging the junk yards until i find either a dana 35 with 3.08 gears or a chrysler 8.25 and the matching front axle to swap my gear ratio. Pretty dang ugly situation. Just a ring and pinion is $167.00. I could probably buy 3-4 complete axles for that...

 

Thankls anyways guys,

Mike.

[gogmorgo]

If you're searching with car-part.com, they split up the axles between 86-87, 88-89, and 90-92. The axles are interchangeable but there may have been minor production changes. There's a chance you find something nearby.

[gitslashgin]

I've found a few "donor" trucks in the area. I'm mainly looking for both axles so i don't have to worry about the gear ratio. So far it's an '88 comanche pioneer or an '89 xj. Both dana 30&35. If not it'll be junkyard time. I also found a guy with a d44 rear and d35 front end. How hard is it to make that d44 accept my Comanche stuff?

[HOrnbrod]

What  was the original mother of the D44?

[gogmorgo]

What's it out of? There was an MJ d44, fairly rare but not quite a unicorn, which will bolt right in. The XJ d44 is identical except for the spring perches, which will need moved, XJ is soa, MJ is sua, and the perches are spaced differently... same as with any XJ axle swap really. Most other d44's will have a different width or lug pattern, but can be made to work.

I just picked up an 8.25 out of an '03 4-banger KJ. 4.10 gears, disc brakes, similar width to the XJ/MJ axles. It'll be a bit more to cut off before welding on perches, but not that big a deal.

[HOrnbrod]

What's it out of? There was an MJ d44, fairly rare but not quite a unicorn, which will bolt right in. The XJ d44 is identical except for the spring perches, which will need moved, XJ is soa, MJ is sua, and the perches are spaced differently... same as with any XJ axle swap really. Most other d44's will have a different width or lug pattern, but can be made to work.

I just picked up an 8.25 out of an '03 4-banger KJ. 4.10 gears, disc brakes, similar width to the XJ/MJ axles.

 

Didn't I just ask that?  :hmm:

[gogmorgo]

Heh, wrote the post and got side-tracked before I hit post. Oops?

[HOrnbrod]

Just raggin' Gog. Your post was better detailed anyhow.  :yes:

[gogmorgo]

:thumbsup:

[yxmj]

I've found a few "donor" trucks in the area. I'm mainly looking for both axles so i don't have to worry about the gear ratio. So far it's an '88 comanche pioneer or an '89 xj. Both dana 30&35. If not it'll be junkyard time. I also found a guy with a d44 rear and d35 front end. How hard is it to make that d44 accept my Comanche stuff?

D35 front? What side is the pumpkin on?

[gitslashgin]

Well, that's what he said. I didn't get those. I just today picked up both front and rear axles from a Comanche. Sad thing is, some pos cut the shock mounts off. Has anyone had experience with making new shock mounts?

[gogmorgo]

How do you mean they were cut off? The shocks don't mount to the axle itself, they've got a stud on the spring plate, which you should be able to reuse from your current MJ. By spring plate, I'm referring to the retainer plate that goes under the spring, that the u-bolts are bolted to.

[HOrnbrod]

http://comancheclub.com/topic/47752-rear-shock-mounting-plate/?hl=reinforcement+plates&do=findComment&comment=487593

 

[gitslashgin]

SWEET! I was really stressed about this over the weekend. Me and my girlfriend were out of town seeing her family, so i didn't have much time to inspect the axles. I just took a good hard look and it appears someone tried to weld something onto the axle housing but it won't be in the way of anything when installed. Pretty stoked up now, I had him pull the covers on both axles prior to purchase so i could take a gander and they were both pretty dang good. It goes in today.

 

Thanks again guys

Mike.